quality audit report of coaching depot bilaspur, sec...

Quality Audit report

Of

Coaching Depot

Bilaspur, SEC Rly

Report no. 10/2012

APRIL 2012

(Audit is done by CRSE, WCR )

of 28 Coaching depot – Bilaspur, S.E.C. Rly April 2012

Quality audit Report of Bilaspur Coaching Depot, S E C Railway

1.0 Introduction

Railway Board vide letter No.2012/M (W/814/5 dated 20.03.2012 has instructed Zonal Railways to conduct quality audit of coaching depots and workshops of other railways. Accordingly WCR has been nominated to do quality audit of BSP depot in SEC Railway. 1.1 Audit team - Shri E.S. Marcus, CRSE/WCR, Shri Nitin Bagh,

SSE/Chg/WCR/HQ/JBP, Shri Lallji Yadav, SE/Chg/WCR/HQ/JBP

1.2 Dates of audit - 03.04.2012 & 04.04.2012. 1.3 Escorting Officials - Sri A. Banarjee, Dy.CME/Chg/HQ/SECR, Shri

Lalit Dhurandhar, Sr.DME/BSP, Shri K. Shrinivas, CDO/BSP, Shri R.S. Gupta, SSE/Gen/BSP.

1.4 Scope of audit: Sick Line, Pit Line, Coaching Depot office, Linen

room, Rolling-in examination points & Stores room etc.

2.0 Brief about Bilaspur Coaching Depot

Bilaspur coaching depot is located at approximately 5 kms from main station towards direction of Katni. It is between up & down main lines of Katni. All the three pits are of 26 coach length CAMTECH design with proper illumination & drainage arrangements. There are two stabling/run-down lines also. The sick line, office of CDO, SSE’s office, stores, canteen, linen room and a captive linen washing plant (under construct) and other facilities are along the length of the pit line and are adjacent to each other. During the two days audit, infrastructures available in the coaching depot, system of working, processes and procedures adopted, record keepings, monitoring and supervision, planning etc., were studied.


3.0 Strengths

3.1 All facilities are nearby i.e. adjacent to each other..

3.2 All pit lines are of CAMTECH design with proper facilities.. 3.3 All pit lines are having connectivity from both ends. 3.4 All pit lines are of 26 coach length and two smaller trains can be

maintained simultaneously. 4.0 Weaknesses

4.1 Bogies are transported from Motibagh workshop at Nagpur. Similarly overhauled wheels are arranged from Wagon repair shop Raipur. These are assembled at BSP.

4.2 Depot is situated between two main lines of BSP-KTE, hence scope of future expansion is limited.

4.3 Movement of staff as well as vehicles is getting affected by crossing

mainline every time they go out or come to depot. 4.4 Pit line capacity is saturated. There is no possibility of new train or

extension of train length. At least one pit line is require for new train.

4.5 Approach road to depot is bad. It involves crossing of main line and

shunting lines which are often blocked. 4.6 There is no dedicated shunting engine for the depot. As a result,

placements and removal of rakes takes longer time. 4.7 The depot doesn’t have spare pool of trolleys. At least 4 are

required. 4.8 Coach history cards are maintained on computerized formats by

filling manually. No computer program is available. The system of using the records does not exist for preventive and corrective maintenance.

4.9 Watering facility is not available in stabling lines.


4.10 High pressure pipe line is not provided along with the pit lines to facilitate efficient & effective cleaning of coaches.

4.11 On platform no 1A, 4 & 6 watering hydrants are provided only for 21

coach length. 4.12 Infrastructure for rolling-in/out examination i.e. lights, huts, location,

height etc. are inadequate. 4.12.1 Unobstructed view is not provided at KTE end of PF 1.

4.12.2 Rolling-in lights are provided with CFL, which are not suitable and

also inadequate. 4.12.3 Staff is provided with LED type lights. However the intensity of

these lights is not adequate enough. 4.12.4 Electronic temperature measuring guns though available are not

calibrated.

4.13 Linen management –

4.13.1 Buffer stock of linen available is highly inadequate. Only one day stock is generally available.

4.13.2 Condemnation of linen is done on age cum condition basis & not as per stipulated frequency.

4.14 The availability of critical spares has been poor. This shall affect the

maintenance of rakes.


Check sheet for Quality-Audit of BSP/SECR coaching depot Primary maintenance attention and sick line attention

(Based on CAMTECH Maintenance Manual for BG coaches and Railway Board / RDSO’s guidelines)

SN Item Clause Observation

1. Periodicity of periodic overhauls (POH) in designated workshops is being followed.

103 of Chg. Manual Table 1.1 and correction slip 5 issued in 2008 RB letter no. 2007/M ( C)/141/1 dtd 26.09.08

Periodicity of POH of coaches is 18 months and IOH 9 months. SECR do not have POH workshop. The coaches are sent to PWP for POH. Bogie IOH is arranged from Motibagh workshop/NGP with wheels from WRS Raipur.

Road transportation is out sourced. ICF Type PCV-469, OCV-76, Total-545

Overdue POH -nil 2. Maintenance schedules to be followed

in coaching depots

To maintain coaching stock in good condition, the following maintenance schedules are prescribed to be carried out in carriage depots on divisions where rake has been based for primary maintenance.

112(a) of Chg. Manual and Correction slip 5 for coaching maintenance manual issued in 2008 RB letter no. 2007/M ( C)/141/1 dtd 26.09.08

Being Followed.

3. Schedule A - Monthly (1 month ± 3 days) in rake

Overdue Sch ‘A’ –nil. Proper facility and record keeping is being followed.

4. Schedule B -Quarterly (3 month ± 7 days) in rake

Overdue Sch ‘B’ –nil. Proper facility and record keeping is being followed.

5. IOH attention - detach coaches Periodicity of IOH attention:

Coach Category

Periodicity

New coach at interval of 12 months in Depot

Rajdhani Satabdi (Conv)

at interval of 9 months in workshop

Mail / Express at interval of 9

months in depot

Passenger at interval of 9

months in depot

Other OCVs at interval of 12 months in depot

Tolerance for IOH may be kept as + 30/-0 days. Maintenance activities to be carried out during schedules should be as per Appendix-F & G. For IOH attention of newly built coaches, guidelines as circulated vide RB’s letter no. 2007/M ( C)/141/1 dtd 06.08.09

Overdue IOH –nil PCVs are being given IOH in 9 months. OCVs/New coaches are being given IOH in 12 months. Overhauled trolleys are arranged from Motibagh/NGP. There is no LHB type, Hybrid, Shatabdi or Rajdhani type coaches in BSP depot.

6. Primary maintenance schedules are required to be carried out by the base depots to which coaches are allotted. In emergency, when due to any reason coaches cannot reach their base depots and primary maintenance schedules become due, A & B schedules should be

112(b) of Chg. Manual

Being followed. Other Railway coaches are not being attended for IOH. Schedule ‘A’ & ‘B’ attention of other depot coaches is also given in case it is required.


SN Item Clause Observation undertaken by the carriage depots where the coaches are available. ‘C’ schedule should be done at base depot.

7. Examination of originating trains: 107 a of Chg. Manual

Being followed

7.1 All trains must be examined by the mechanical train examining staff before despatch to ensure all coaches are in fit condition without rejectable defects.

107 a (i) of Chg. Manual

The depot is giving PM to 11 trains. No documentary evidence was found that any coach is in service with rejectable defect.

8. Terminating Examination of Passenger Trains – Rolling in examination.

107 b of Chg. Manual

There are 8 platforms at BSP. 3 platforms have dead ends. Hence total requirement of lights are 26, but there are only 22 lights due to swivel type lights at 4 locations. Infrastructure for rolling-in/out examination i.e. lights, huts, location, height etc are not adequate. These are non standard.

8.1 Site shall provide unobstructed view of under gear from both sides.

107 (b)(i)(a) of Chg. Manual

Unobstructed view is not provided at KTE end of PF-1. Locations are not chosen judicially. Height of the lamp is also not proper. Proper huts are not provided.

8.2 Should have adequate space for fixing the lighting arrangement and for staff

107 (b)(i)(d) of Chg. Manual

Rolling-in lights consisting of single metal halide lamps. The intensity of light is inadequate. Swivel type lights provided at 4 locations are inadequate and not suitable for job. Unlike CFLs, Metal halide lamps do not light-up instantly due to presence of choke. Hence are rendered useless upto 10 minutes after a power interruption. Hence, a suitable alteration/arrangement should be made.

8.3 As the train passes the nominated point, C&W staff should watch out vigilantly for loose/hanging/broken under gear parts of the coaches, any unusual sound coming from the coaches or any other abnormality in the coaches.

107(b)(iv) of Chg. Manual

C&W staff is deployed to watch for loose/hanging/broken parts of under gear. Staffs are provided with LED type lights. The intensity of such lights is inadequate.

8.4 Temperature of the axle boxes should be measured preferably with the help of the electronic temperature measuring device.

107(b)(vi) of Chg. Manual

There are 11 electronic temperature measuring guns. 6 guns were in use, 2 guns in each gang. Electronic temperature measuring guns are not calibrated.

9. Revised maintenance pattern for coaching trains circulated vide Railway Board’s letter No.95/M(C)/141/1 dt.31.01.07

Railway Board’s letter No.95/M(C)/141/1 dt.31.01.07

Trains are being maintained as per RPC-4

9.1 While permitting introduction of round trip primary pattern of maintenance on coaching trains, approved mandatory condition at primary end and other end as

Railway Board’s letter No.95/M(C)/141/1

Being followed


SN Item Clause Observation detailed in Railway Board’s letter No.95/M(C)/141/1 dt.31.01.07 is followed.

dt.31.01.07

9.1.1 Primary End

i) The brake gearing should be properly adjusted including the slack adjuster ‘A’ dimension & the brake cylinder stroke to ensure 100% brake power

-do- Being followed

ii) Brake blocks should be changed in bogie sets only

-do- Being followed

iii) All missing passenger amenity fittings must be replaced and the rake must be turned out as ‘Zero-Missing-Fitting’ rake.

-do- Being followed

iv) Intensive cleaning of coach toilets and lavatory.

-do- Being done (Mechanized cleaning contract is available)

v) Clear maintenance time of 6 hours on the pit as per train schedule.

-do- Being given

vi) Provision of proper washing cum maintenance pit line facility with adequate testing equipment and high pressure jet cleaning plant at primary end.

-do- Yes, 3 pit lies of 26 coach length as per CAMTECH are available. Mechanized cleaning contact is available and working satisfactorily.

vii) Adequate gang strength with proper supervision

-do- Sanctioned strength -499 Man on roll- 442 (including 30 supervisors)

9.1.2 The Other End

i) Whenever the lie-over is more than 2 hours at the platform or the rake is stabled in the yard, the rake should be locked and positive security should be provided

-do- Being followed

ii) The minimum infrastructure to be provided at the platforms from where trains are returned without secondary maintenance should be available

-do- Available

iii) A joint safety certificate covering each clause of mandatory conditions will be issued by mechanical and operating branches at divisional level prior to changing over any train to revised coaching maintenance pattern.

-do- Yes

10. Rake maintenance link has provision of maintenance time (pit attention) of 6 hrs at primary end to enable intensive attention.

108 of Chg. Manual and Policy circular no. 4

6 hrs time available at primary end.

11. Internal cleaning, Passenger amenity attention and watering is done at platform line or nominated stabling line provided stipulated facilities are available at such line is followed

108 of Chg. Manual Table 1.8

Watering facilities are not available in stabling lines.

12. Washing and cleaning of coaches 109 of Chg. Manual

12.1 Use recommended solutions for cleaning as per RDSO specification No. M&C/PCN/101/2001 or use cleaning agents approved by CME of the Railway

109 of Chg. Manual

RDSO Recommended solutions for cleaning through approved sources are being used by the contractor.

12.2 It should be ensured that the rake/coach is protected with proper board/signal for safety of the staff working on washing/cleaning job to prevent

109 (b)(i) of Chg. Manual

Being followed


SN Item Clause Observation movement/disturbance in the activity. Scotch blocks with locking arrangement should protect lines and keys should be kept with Engineer (C&W) till the time rake is under maintenance

12.3 External cleaning /washing: Check that guidelines as detailed in CAMTECH manual are being followed.

109 (b) of Chg. Manual

Being followed

12.4 Cleaning of Toilet: Check that guidelines as detailed in CAMTECH manual are being followed.

109 (c) of Chg. Manual

Being followed

12.5 Internal cleaning of upper class AC and sleeper coaches: Check that guidelines as detailed in CAMTECH manual are being followed.

109 (d) of Chg. Manual

Being followed

12.6 Internal cleaning of GS, SLR: Check that guidelines as detailed in CAMTECH manual are being followed.

109(e) of Chg. Manual

Being followed

12.7 Cleaning of buffers and screw couplings 109(f) of Chg. Manual

Being followed

(i) Buffer plungers should be scrubbed with a scraper to remove dirt and muck. Thereafter, they should be wiped clean with cleaning oil and rubbed with coir rope.

109(f)(i) of Chg. Manual

Buffer plungers are scrubbed with a scrubber to remove dirt and muck.

(ii) Screw coupling threads should be cleaned with wire brush to remove all dirt and dust. Thereafter, it should be cleaned and given a light coat of oil. Oiling should be done on slack adjuster also

109(f)(ii) of Chg. Manual

Being followed

13. Conditions required for maintenance of 24 coach trains (Railway Board’s letter No.98/M(C)/137/19 Pt.I dt.28.7.99 & 5.5.2000

110 of Chg. Manual

13.1 Infrastructural requirements 110(a) of Chg. Manual

(i) 24 coach length fully equipped pit line. 110(a)(i) of Chg. Manual

All the 3 pit lines are of 26 coach length as per CAMTECH design with full facilities having connectivity form both ends.

(ii) High pressure jet cleaning pipeline with plant for cleaning at primary pit line. Mechanized external cleaning is preferable

110(a)(ii) of Chg. Manual

Contract for mechanized cleaning of coaches is in place. Under the scope of this contract, high pressure jet cleaning is being done for toilet and external cleaning of coaches. High pressure pipe line along the length of the pit line is not available. Portable compressors are used for external coach washing & toilet cleaning.

(iii) Water hydrants for 24 coach length at en route watering stations with 20 minutes stoppage at nominated stations

110(a)(iii) of Chg. Manual

There are 8 platforms at BSP. Water hydrants of 21 coach length are available on platform no. 1A, 4 & 6. Rest all the platforms have water hydrants for 24 coach length. Trains are having adequate stoppage time nominated for en-route watering at BSP.


SN Item Clause Observation (iv) Availability of the prescribed air brake

maintenance and testing equipment 110(a)(iv) of Chg. Manual

Available

13.2 Coach Design related requirements 110(b) of Chg. Manual

(i) Air brake with twin pipe graduated release system

110(b)(i) of Chg. Manual

Yes, all coaches are provided with twin pipe graduated release brake system.

(ii) Only enhanced capacity draw gear and screw coupling to RDSO sketch No. 79061 and 79067 are to be provided on the rake

110(b)(ii) of Chg. Manual

Yes, all coaches are provided with enhanced capacity draw gear screw coupling.

13.3 Maintenance practices and system related requirements

110(c) of Chg. Manual

i) The integrity of the rakes to be maintained.

110(c)(i) of Chg. Manual

Being maintained

ii) Primary maintenance of the rake should be done in one hook without splitting

110(c)(ii) of Chg. Manual

Being done in one hook. There is no splitting.

iii) Minimum maintenance time of 6 hours on the pit during primary maintenance

110(c)(iii) of Chg. Manual

6 hrs is being given

iv) It is mandatory to provide secondary maintenance to all trains augmented to 24 coaches (RPC 4 revised and permit Round trip attention with approval of CME)

110(c)(iv) of Chg. Manual

There is no train of 24 coach length being maintained at BSP depot.

v) Trains leakage rate to be maintained within prescribed limits by using rake test rig.

110(c)(v) of Chg. Manual

Being followed

vi) Provision of proportionate brake system on the locomotive in good working order

110(c)(vi) of Chg. Manual

yes

vii) Provision of audio visual alarm system on the locomotive

110(c)(vii) of Chg. Manual

Yes

14. Fire extinguishers should be checked every three months and completely refilled after one year.


Maintenance, checking and refilling has been outsourced and it has been checked that fire extinguishers are checked in every three months and refilled in one year.

14.1 Provision of DCP type fire extinguisher in a rake should be in accordance with guidelines circulated vide letter no. 95/Sec (spl)/75/1 dtd 30.05.97

Coach type Nos of FE’s

Each Break Van 2 nos

Each AC coach 2 nos

Each Pantry car 4 nos

Each Generator van

2 nos

RB’s letter no. 95/Sec (spl)/75/1 dtd 30.05.97

Yes. Being followed and provided

15. Similarly, other brake van equipment, which Mechanical Train Examining staff is responsible to supply, should be provided according to the instructions of each Railway. Portable control telephones, portable train lighting equipments, portable fire extinguisher, wooden wedges/skids and stretcher are to be provided.

111(g)(i) of Chg. Manual

All brake van equipments are provided in the cupboard of brake van and sealed with special type of locks which can only be opened by its distruction. Stickers are provided with list of items, date of testing and place for signing by CDO.


SN Item Clause Observation 16. Watering and cleaning of rakes

Mechanical department of each railway will nominate the watering and the cleaning stations on the railway.

111(h) of Chg. Manual

BSP is the nominated watering station of SECR. There is no CTS activity at BSP.

17. Deficiency Rolling Stock (DRS) for Coaching Stock

111(i) (i) of

(i) Railway should devise system for detecting deficiencies. Reports of deficiencies/ defects in Rolling Stock (DRS) reports in the proforma given in Annexure 1.2, should be prepared for each mail/express/passenger originating train in duplicate by the Engineer (C&W)/Electrical (TL) and should be signed jointly with the RPF representatives.

Chg. Manual Being followed

(ii) On arrival of the train at the destination station,, the Engineer (C&W) staff and electrical staff shall check the rakes jointly with a representative of RPF and comparison may be made with original report.

111(5)(b) of Chg. Manual

Being followed

18. Coach Maintenance History Card 111(k)(i) of

(i) Every coaching depot shall have computers for maintaining the coach maintenance history in a software programme which should be compatible with the programme of the coaching workshop.

Chg. Manual History card of coaches are maintained on computerized format but details are entered manually. Regular updating need to be ensured. The coach history is maintained in MS Word. 4 computers with printers are available at depot.

(ii) The complete history book of each coach, consisting of maintenance history cards, date card, trial card, etc. will, however, be maintained by the base workshops

111(k)(iii) of Chg. Manual

There is no POH workshop over SECR. Hence, a coach history is being maintained at BSP coaching depot.

19. Primary/Secondary maintenance 19.1 The rakes/ coaches of all trains should be

given a Primary/Secondary Maintenance examination as prescribed by the Chief Mechanical Engineer of the Railway and as per Appendix F of Chg. Manual

113(a) of Chg. Manual

11 pairs of trains are given primary attention and 4 pairs are given secondary attention. There are 2 platform return trains.

19.2 Coaches shall be washed and cleaned thoroughly from outside and inside as prescribed in clause 109.


Being followed through contract.

19.3 Brake system maintenance Air brake system (Bogie mounted and underframe mounted):

Attention as detailed in para 113 (c) is being given during primary /secondary attention of a rake.


The entire requirement laid down in para 113 (c) is being followed during PM & SM. 2 nos RTR and 3 nos of STR are available in the depot. There is no facility for overhauling of defective DVs. Hence, lots of defective DVs are accumulated since KGPW & MTNS depots have refused to overhaul them.


SN Item Clause Observation 19.4 In addition to above the following items of

work should be attended during the maintenance schedule examination: * under frames * bogie frames * axle boxes * springs. These items should be wiped with wet waste weaves or cotton waste as necessary so as to facilitate examination. All under gear components should then be examined and repaired as necessary to ensure that there is no `S' marked rejectable defect as mentioned in Chapter IV of IRCA Conference Rules.


Being followed

19.5 The following items of under gear components should, however, be specially examined and attended to:-

113 (e) of Chg. Manual

i) Oil in hydraulic dash pots of Rajdhani and Shatabdi coaches should be checked once in 15 days to detect oil leakage from them through defective seals or through the vent screw. Add/ replenish with specified grade of oil if the oil level is below 40 mm in the tare condition for ensuring better riding comfort.

113 (e) (i) of Chg. Manual

There is no Rajdhani/Shatabdi train. For other it is being followed.

ii) Wheel profiles should be visually examined and gauged in case they appear to be near condemning limits.

113(e)(ii) of Chg. Manual

Being followed. Gauges are available. Knowledge of staff was found satisfactory.

iii) The brake gear should be checked and so adjusted that the piston stroke is within the limits specified for different types of coaches. (see table 1.10). 'A' and 'e' dimensions for slack adjuster should be as per table 1.11 (as applicable for under frame mounted brake system)

113(e)(iii) of Chg. Manual

Being followed

19.6 The following coach body components and fittings should be specially checked and attended to

113 (f) of Chg. Manual

i) Doors should be properly secured with the hinges/pivots and should not be grazing with floor or door sill plates.


Being attended

ii) Door latches and safety catches 113(f)(ii) of Chg. Manual

Being attended

iii) Door lock handles 113(f)(iii) of Chg. Manual

Being attended

iv) Tower bolts 113(f)(iv) of Chg. Manual

Being attended

v) Window shutters should neither be tight nor loose

113(f)(v) of Chg. Manual

Being attended

vi) Window shutter safety catches 113(f)(vi) of Chg. Manual

Being attended

vii) Window frame 113(f)(vii) of Chg. Manual

Being attended

viii) Vestibule assemblies of all vestibule coaches should be checked and repaired as necessary.

113(f)(viii) of Chg. Manual

Being attended


SN Item Clause Observation ix) Water pipe connections, flushing valves,

cocks and shower roses should not be leaking or choked.

113(f)(x) of Chg. Manual

Being attended

x) Drain grills and drain holes in the bathroom floors and wash basin drainpipes should be cleaned and opened where found choked.

113(f)(xi) of Chg. Manual

Being attended

xi) Any other deficiency as per Annexure 1.2 should be made good.

113(f)(xii) of Chg. Manual

Being attended

xii) A proper record should be kept by Engineer (C&W) at washing/pit lines of schedules carried out by them, especially of items required to be attended at specific periodicity. Record to be maintained in standard DDR (Damage deficiency register)

113(h) of Chg. Manual

Being done. Records checked.

20. Schedule ‘A’ Examination 114 of Chg. Manual

i. Schedule `A' is required to be given every month + 3 days at the nominated primary maintenance depot within the normal primary maintenance time on a washing/pit line in a rake.

114 (a) of Chg. Manual

Being followed

ii. Brake system maintenance Air brake system (bogie mounted) A schedule maintenance as per air brake chapter.


Being followed

iii. The specified items of work should be attended during Schedule ‘A’ examination, i.e. monthly examination:-


Being followed

21. Schedule ‘B’ Examination 115 of Chg. Manual

i. Schedule `B' is required to be given every three months + 7 days at the nominated primary maintenance depot within the normal time allowed for primary maintenance on a washing line in rake.

115(a) of Chg. Manual

Being followed

ii. The specified items of work should be attended.

115(b) of Being followed

iii. Brake system maintenance

Air brake system (Bogie mounted) (i) Same as 'A' schedule


iv. Other assembly maintenance

Besides brake system other items should be attended as given below:

115(b)(i) of Chg. Manual

Being followed

a. All items of Schedule `A' 115(b)(ii) of Chg. Manual

Being followed

b. Painting of lavatories from inside. 115(b)(iii) of Chg. Manual

Not being followed

c. Thorough inspection and repairs of brake gear components.

115(b)(iv) of Chg. Manual

Being followed

d. Thorough checking of trough floor, turn unders, etc., from underneath for corrosion.

115(b)(v) of Chg. Manual

Being followed

e. Touching up of painted portion, if faded or soiled.

115(b)(vi) of Chg. Manual

Being followed


SN Item Clause Observation 22. IOH attention

116 of Chg. Manual and Correction slip 5 for coaching maintenance manual issued in 2008

22.1 Periodicity of IOH attention:

Coach Category

Periodicity

New coach at interval of 12 months in Depot

Rajdhani Satabdi (Conv)

at interval of 9 months in workshop

Mail / Express at interval of 9

months in depot

Passenger at interval of 9

months in depot

Other OCVs at interval of 12 months in depot

Tolerance for IOH may be kept as + 30/-0 days. Maintenance activities to be carried out during schedules should be as per Appendix-F & G. For IOH attention of newly built coaches, guidelines as circulated vide RB’s letter no. 2007/M ( C)/141/1 dtd 06.08.09

117(i) of Chg. Manual and correction slip 5 for coaching maintenance manual issued in 2008

Being followed

22.2 Coaches are required to be detached from the rake and taken to the sick line or sent to shop for IOH attention (‘C’ schedule maintenance)

117(ii) of Chg. Manual and Correction slip 5 for coaching maintenance manual issued in 2008

Being followed Upper gear of coach is given attention at sick line. Overhauled trolleys received from Motibagh/NGP are put in coaches. Synchronization of alternators is also done at sick line.

22.3 Brake system: ‘C’ schedule maintenance

(IOH) as per para 426 of air brake chapter.

117(a)(i) of Chg. Manual

Being followed

22.4 Thoroughly clean Dirt collector filter in kerosene or replace on condition basis.

117(a)(vii) of Chg. Manual

Being followed

22.5 Other assemblies maintenance

All items of Schedule `B' 117(a)(i) of Chg. Manual

Being followed

22.6 Thorough repairs of running gear including running out of bogies where considered necessary. All bogies which are working on rake links earning more than 2.5 lakhs kms. per annum must however be run out and thoroughly attended to as laid down in clause 111c under “Intermediate Overhaul”.

117(a)(ii) of Chg. Manual

Being followed

22.7 Touching up damaged paint of coaches on outside as well as inside.

117(a)(iii) of Chg. Manual

Being followed


SN Item Clause Observation 22.8 Polishing of the polished surfaces. 117(a)(iv) of


22.9 Shock absorbers should be replaced and sent to the base workshops for repairs, testing and return. For this purpose, adequate spares must be maintained in the depot.

117(a)(v) of Chg. Manual

Being followed

22.10 Thorough cleaning and removal of dust, rust, dirt, etc., accumulated at the pillars through the turn under holes, with coir brush and compressed air.

117(a)(vi) of Chg. Manual

Being followed

22.11 Thorough examination and repairs of upholstery, cushions, curtains, etc.

117(a)(vii) of Chg. Manual

Yes

22.12 Thorough checking and full repairs of all window shutters, safety catches, safety latches, staples and hasps of compartment, lavatory,

117(a)(viii) of Chg. Manual

Yes

22.13 Thorough checking and repairs of UIC vestibules, their rubber flanges metal frames, doors, fall plate, locking gear, etc., for ease of operation and safety

117(a)(ix) of Chg. Manual

Yes

22.14 Thorough checking and repairs of all cracks and worn out portions of flooring of the compartments.

117(a)(x) of Chg. Manual

Yes

22.15 Engineer (C&W) of Primary Coaching Maintenance Depots should be fully familiar with the vulnerable areas of ICF coaches for corrosion, viz., sole bar at doorways, lavatories and adjoining areas, corridor sides - more so in case of those SLRs which are used for Fish, Salt, etc. For facilitating inspection of sole bars even spaced elongated holes of (215x127 mm) are already provided in the turn unders.


Yes

22.16 Special attention should be taken for the following:-

117(e) of Chg. Manual

i) Pocket between sole bars and turn unders should be thoroughly cleaned through the inspection opening of the sole bars and inspected with the help of torch light or inspection lamps.

117(e)(i) of Chg. Manual

Being done

II). Drain holes provided in the trough floors should be kept clean and unclogged. If during the cleaning of these drain holes any accumulation of water is observed, the affected area should be very carefully inspected for possible corrosion.

117(e)(ii) of Chg. Manual

Being done

III) A register should be maintained of the primary maintenance coaches on the subject. Record of Schedule A, B and IOH attention are maintained in standard format and records are maintained.

117(e)(iii) of Chg. Manual

Being done

22.17

For maintenance of coaches of Rajdhani/ Shatabdi Express Rakes, the instructions given in RDSO Technical Pamphlet No. C-7807 should be followed.

118 (b) of Chg. Manual

Not applicable as no Rajdhani/Shatabdi train is based at BSP.


SN Item Clause Observation 22.18 The IOH of Rajdhani/Shatabdi high speed

coaches should be carried out in workshops


Not applicable as no Rajdhani/Shatabdi train is based at BSP.

23 Linen management

i. Complete activity of linen management including washing, storage, supply & distribution of linen kits in trains shall be done by Mechanical (C&W) Dept as a single window agency

Board’s letter No.2009/M(C)/165/6 dt.17.12.2009.

Mechanized washing, storage & supply of linen is done by Mechanical department on contract basis. Distribution in train is with Electrical department. A building for captive linen washing plant is under construction.

ii.(a) Stock verification of linen should be carried out on a quarterly basis

Board’s letter No.2009/M(C)/165/6 dt.4.1.2010

Being done

ii.(b) At least 5% of new linen should be checked by SSE/Mechanical for: (a) bundles being sealed and having batch nos., manufacturer’s name, year of manufacture, quantity, size indicated, (b) Linen items having marking of month / year of manufacture, Railway, etc. (c) dimensional check, colour, feel and workmanship, etc.

Being done

ii.(c) Monthly report of inspections / test checks of the linen washing contractor’s

premises by officers / supervisors, should be prepared and payment should be made after recovery of all penalties / dues

Being done

ii.(d) Enough buffer stock of linen to last for 2 to 3 days is available

Buffer stock Available for only one day.

ii.(e) Life of linen is adhered to: Bed sheets : 12 months for khadi, 24 months for poly vastra Pillow cover/face towel : 9 months Pillow : 24 months Blanket : 48 months

Condemnation of linen is done on age cum condition basis.

ii.(f) Committee nominated by DRM for linen condemnation on condition basis

Yes

iii. Specified frequency of washing/dry cleaning of blankets and other linen items is adhered to

Yes

23.1 Passenger complaint on account of linen is analysed and corrective & preventive action is taken

Yes

23.2 Feedback on linen quality is obtained through coach attendant as per RB’s guidelines

Yes. Surprise inspections are carried out by railway supervisors in running trains. Data is analyzed and penalty is imposed in case of passenger complaints and poor quality of cleaning.

24. Pest / Rodent Control

i. Comprehensive contract covering pest / rodent control in coaches and rodent control in pit lines / coaching depot yards awarded for 3 years under two packet system

Board’s letter No.2010(M)/C/141/7 Vol.IV dt.21.12.2010

Pest & Rodent control is being done by specialized agency. The contract was done by two packet system.

ii. All reserved (both AC and Non-AC) covered under contract, unreserved

Yes covered.


SN Item Clause Observation coaches may also be covered as per requirement of Railways

iii. Minimum frequency of pest control treatment is adhered to : AC coaches / Pantry cars : Fortnightly, Reserved Non-AC coaches : Fortnightly in first 3 months, monthly thereafter, Unreserved Non-AC coaches : Bi-monthly Maximum tolerance +7 days, on account of operational exigencies, disturbance of rake links, etc.

Being followed.

iv. Chemicals to be used (with brand names), concentration, dose specified

Yes

v. Minimum frequency of rodent control treatment is adhered to : AC coaches / Pantry cars : during every Primary maintenance, Reserved Non-AC coaches : Weekly Maximum tolerance +7 days, on account of operational exigencies, disturbance of rake links, etc.

Yes

vi. Personnel trained by certified training institutes deputed for pest/rodent control

Pest & Rodent control is out sourced to specialized agency, hence personal employed by the contractor are trained.

vii. Fumigation/mist treatment carried out whenever coaches detached for IOH/POH. Pest/rodent control carried out before inducting the coach in service after IOH/POH

Yes

viii. In order to prevent cross infestation, contractor may make effort to treat all AC and all Non-AC coaches of a particular rake together

Yes

ix. Stickers indication date of pest control and next due date provided in doorway/toilet area

Yes

x. Railways shall make effort to detach pantry cars from rakes once a month (within reasonable tolerance) to facilitate complete vacation and intensive cleaning for thorough pest / rodent control treatment

There are seven pantry cars in BSP depot. Pantry cars are vacated completely once a month for pest and rodent treatment.

xi. Broad methodology for measuring the level of infestation of cockroaches and rodents and expected reduction over time is in place

By counting the number of dead and live pests after treatment.

24.1 Passenger complaints on account of pest are analysed and corrective action is taken.

Feedback is collected and analyzed. Penalty is imposed as per contract provisions in case of complaints.

25. Passenger amenities provided in various

types of coaches as specified Board’s letter No.2006/M(C)/141/26 dt.21.12.2006

Yes

26. Infrastructure facilities – Standard

integrated modular pit line have unified maintenance.

Appendix ‘E’ of Coaching manual CAMTECH report No. CAMTECH/M

Total 3 nos of pit lines available. All are CAMTECH design pit lines of 26 coach lengths. Pit lights and portal lights are available in all the pit lines.


SN Item Clause Observation /99/Infra-washing line/1.1

27 Examination and repair practice in carriage maintenance depot for wheel sets and roller bearing

Para 1009 of Chg manual

27.1 Wheel and axle Para 1009 a of Chg manual

i) Wheel profile should be checked with Tyre defect gauge to ensure the profile dimensions are within the Permissible limits.

Yes, gauges are available to check wheel profile.

ii) Limits for flat tyres The limits for permissible maximum flat surfaces on tread for BG ICF coaches is 50 mm (reference Rly. Bd.'s Letter no. 83/M (N)/960/1/Vol I dated 15/18.3.99)

Yes

iii) Guidelines for wheel inspection in open line depots (Ref RDSO CMIK003)

In addition to normal checks exercised on wheel condition during primary/secondary maintenance of coaches, a detailed inspection of wheels should be done when the coaches are received in sickline for attention for either schedules or out of course attention. The wheels sets shall be inspected for the following conditions and action taken as indicated for each condition:

Being done

a) Shattered Rim Being done

b) Spread Rim Being done

c) Shelled Tread Being done

d) Thermal Cracks Being done

e) Heat checks Being done

iv) The defective wheel should be sent to workshop for repairs after entering in the maintenance card details of the work order and date of dispatch to Workshop.

Being followed

v) No repairs, except wheel profiling of wheel sets is permitted to be done in the maintenance depot.

Being followed

27.2 Roller Bearing Axle Boxes Para 1009 b of Chg manual

i) A coach should invariably be detached from service for the following defects i) Hot axle box ii) Damaged axle box iii) Damaged front or rear cover iv) Seized roller bearing v) Coach involved in accident, derailment, fire, flood etc.

Coaches for these defects are immediately detached from service and necessary actions are being taken for repairs.

ii) Care should be taken not to keep a coach fitted with roller bearing stationary for a long time. Coaches grounded for a long time should be shunted up and down at

Being followed


SN Item Clause Observation regular intervals. Coaches fitted with roller bearing should be checked to ensure that :- i) No wash basin drain hole / discharge pipe is directly above the axle box ii) The front and rear covers of the axle boxes are not damaged, cracked or loose iii) Clearance between axle box and wheel is such that the axle box does not bind against the wheel. iv) Brake gear is properly adjusted to avoid possibility of brake binding

27.2.1 Axle box is examined for grease oozing out from rear cover and corrective action is taken. Concerned shop needs to be advised for necessary corrective and preventive action.

Yes

27.3 Axle box temperature measurement by non contact type temperature measuring instrument during rolling in examination:

Carriage Dte/RDSO letter no. MC /AB dtd 21.08.09

Thermal guns are being used for measurement of axle box temperature during rolling-in/out examination. 11 guns are available. 6 guns are issued, 2 in each gang.

i) Temperature to be checked at axle box top (crown) at front face of axle

Being followed

ii) If temperature is found above 800 C, the

affected coach will be detached. Yes

27.4 Minimum permissible wheel diameter in ICH design BG coaches.

RB letter no. 92/M (C)/137/2 Vol V dtd 25.1.11

i) Shop issue size of wheel set should be 837 mm

Being followed

ii) Condemning diameter of the wheel in service, measured at a distance of 66.5 mm from the outer face of the rim shall be 825 mm.

Being followed

28 Attention brake block hangers on ICF coaches – to avoid failures

Carriage Dte/RDSO letter no. MC /ICF/B/D dtd 03.07.09

28.1 The new brake block should be procured as per revised spec C – 9808 Rev 2 and drg no. SK – 93286 Alt 5

New brake block hangers are being provided in overhauled trolleys received from Motibagh workshop, NGP. Approximately 20% coaches of BSP depot have been provided with new brake block hangers.

28.2 Maintenance of brake gear rigging should be given as per guidelines circulated by ED/Carriage /RDSO vide letter no. MC /ICF/B/D dtd 03.07.09

Being done

29 Other items:

29.1 Changing of air brake hose pipe: Air brake hose pipe to be changed in every alternate POH attention.

Carriage Dte/RDSO letter no. MC /APB dtd 19.02.09

Yes

29.2 Fire retardant items are provided in coaches as per RDSO specification.

RDSO spec and STR

Yes, provided by workshop.


SN Item Clause Observation 29.3 FAC amenities are provided as per

guidelines circulated vide DG/Carrg/RDSO’s letter no. MC/CB/AC/BG dtd 28.04.10


29.4 Additional amenities / facilities in GSCN type of coaches are provided as under:

Snack table in each bay. Mirrors in each bay Magazine holders on partition

wall Bottle and tumbler holder

RB letter no. 2004 / M (C)/165/16 dtd 29.03.05


29.5 Maintenance of Duronto express:

i) Pattern of maintenance for Duronto train as being followed for Rajdhani trains with pit examination at both end should also be follwed.

RB letter no. 2009/M (C)/141/2 dtd 25.08.09

There is no Duronto Exp. Train in BSP

ii) Rolling – in and rolling- out examination may also be conducted for each of the Duronto trains at the respective operational halts and also at the terminals during the journey. Such safety examinations of the Duronto trains may be periodically super checked at the level of officers.


Not applicable

iii) Short distance Duronto with only only AC / Non AC chair car may be permitted to run on the extant pattern for Shatabdi trains with a terminal attention at other end on platform / stabling line. A minimum 2 hrs may be planned at the non primary end to enable thorough attention to cleanliness, hygiene and passenger amenities at other end.


Not applicable

iv) Cleaning of Vinyl wrapping on Duranto rake coaches Mild detergent should be used with normal jet of water. High pressure water jet should not be directed towards Vinyl wrapping.

RCF’s letter no. MD 22.151 dtd 09.02.10

Not applicable

29.6 Attention of air springs ED/Carrg/RDSO’s letter no. MC/CB/MM dtd 09.09.2009 & Maintenance manual of air spring for mainline ICF bogie coaches RDSO/2009/CG/CMI-01, Sep’09

Procedure for rolling – in examination: As train passes the nominated point, C&W staff should watch out vigilantly loose / hanging / broken under gear parts of the coaches special attention should be paid to air springs in case of coaches provided with air springs at secondary suspension stage. It should be ensured all the air springs are in inflated condition by noting that the levelling valve lever is in horizontal position. In case it is not feasible to inflate the air springs of any particular coach, these should be isolated by air spring isolating cock and speed of train should be reduced to 60 Kmph or the coach should be detached.

No coach with air spring is based at BSP depot

29.7 Analysis of sick marking and en-route coach detachment

i) Whether primary coach detachment is analysed and corrective & preventive

Being done


SN Item Clause Observation action taken. Details of primary detachment for last 3 years to be collected.

ii) Whether secondary detachment is being analysed and corrective & preventive action taken. Details of secondary detachment for last 3 years to be collected.

Being done. There were 8, 6 & 7 coaches were detached during the year 2009-10, 2010-11 & 2011-12 respectively.

iii) Whether en-route coach detachment is investigated and corrective & preventive action taken. Details of en-route coach detachment for last 3 years to be collected with investigation report.

Being done. There was no En-route coach detachment on ownership basis during the year 2009-10, 2010-11 & 2011-12. There was only one coach detachment on territorial basis in last three years.

29.8 Facilities for pit line and sick line attention

CAMTECH Maintenance Manual for BG Coaches of ICF design, 1

st correction

slip– CAMTECH/2002/M/C/ CMM/1.0/CS-01(07.2006)

i) Facilities available as per CAMTECH guidelines as detailed in annexure – I to be observed.

Yes

30 Passenger satisfaction

30.1 OBHS & escorting of trains

i) Whether depot has provision of OBHS as per RB policy guidelines.

Yes

ii) Nos of Mail Express train in which escorting staff have been provided with cleaning staff by depot.

7 trains are provided with OBHS facility on contract basis. Escorting staff of contractor is provided in these trains.

iii) Nos of Mail / Express trains in which OBHS have been provided.

Seven

iv) Nos of Mail/ Express train in which no staff from depot and OBHS through contract have been provided.

Seven Super checking is done by Railway supervisors.

v) Average PSI for OBHS implemented rakes. Whether systems to cross verify PSI in OBHS provided train is existing.

PSI for OBHS is being collected. Payment to the contractor is linked with PSI score as per provisions of contract agreement.

30.2 Whether depot has system to get feedback of cleanliness, linen quality and pest infection of Mail/ Express trains. Action taken by depot on the basis of feedback from passenger.

Yes. A format for passenger feed back is given to escorting staff. The format is signed by supervisors at the other end and brought back to base depot.

30.3 Whether depot has system to analyse passenger complain and takes corrective action. Passenger complains for last three years with action taken to be submitted.

The depot has system to analyze passenger complain. No complaints have been received.

30.4 Whether depot has facility for mechanised cleaning of coaches. List of equipments and nos of rakes covered in every month to be submitted.

Mechanized cleaning of coaches is done by contractor.

30.5 Whether depot has facility for upholstery and carpet cleaning either through in-house or through contract. Efficacy of cleaning to be observed.

Three vacuum cleaners are available in the depot for carpet cleaning.


SN Item Clause Observation 30.6 Whether curtains are cleaned at

prescribed interval of 15 days as per RB guidelines

Yes

30.7 Whether blankets are cleaned at one month interval as per RB guidelines

Yes

30.8 Compliance of CRB letter to GM for sustainable image makeover of the Railways:

CRB DO no. 2011/ER/6018 dtd 28.07.11

i) Cleanliness of coaches:

a) Ensure high standards of cleanliness in the coaching maintenance depot particularly in the washing line area.

Yes, being followed through contract.

b) Action in respect of implementation of systems of system for collection bagging and disposal of leftover food from pantry cars and coaches.


c) Sustainable garbage collection and disposal system


d) Functional and efficient drainage to avoid water logging and dirt collection

Drains are in good condition.

e) Periodic fumigation of coaches and high standards of cleanliness in washing lines

Yes

f) Monitoring the functioning of OBHS and CTS scheme.

Being done.

g) At the Zonal / Divisional level, SAG / Selection grade officers by name and designation may be put in –charge of important Mail/Express trains under “Own your train scheme (OYTS)” with responsibility being taken by the officers for the areas for which they have been nominated.

Yes, being followed.

ii) Quality of linen supplied on trains:

a) Availability of clean and hygienic linen to passenger through washing quality, adequate quantity, replenishment with new linen on age / condition basis, use of washable blankets and appropriate quality of packing.

Made available

b) Commissioning of mechanized laundries at critical locations dealing with large quantity of linens

Building for captive linen washing plant is near completion. Machines will be bought by Railway and outsourced for operation. Requirement is 2 ton per day.

c) System of packaging, storage and servicing of the linen to the passenger must be streamlined.

Yes. Being followed

31 LHB coach attention: There is no holding of LHB coaches Not Applicable.(NA)

31.1 Periodicity of periodic overhauls (POH) in designated workshops is being followed.

Schedule Periodicity

IOH (Shop Sch I) 18 months / 5 lakh Km

POH (Shop Sch II)

3 yrs/ 10 lakh Km

POH (Shop Sch III)

6 yrs / 20 Lakh Km

RB’s letter no. 95 /M (C)/ 141 (LHB) dtd 22.08.06

NA


SN Item Clause Observation 31.2 Attention to following components are

being given as per Alsthom manual guidelines and guidelines circulated by RDSO. Phonic wheel / speed sensor. Dump valve Earthing device. Control arm Dampers

Primary vertical dampers. Secondary vertical dampers Yaw damper. Secondary lateral damper

Primary and secondary springs Disc brake attention CDTS (Controlled discharge toilet

system)

Alsthom manual and OEM manuals

NA

31.3 Wheel sets and CTRB attention at depot:

NA

i) The wheels sets shall be inspected for the following conditions and action taken as indicated for each condition: Shattered Rim Spread Rim Shelled Tread Thermal Cracks Heat checks

Para 1009 a (iii) of chg manual

NA

ii) Wheel profile should be checked with Tyre defect gauge to ensure the profile dimensions are within the permissible limits. Coaches with wheels having thickness and profile worn below condemning limit should not be allowed to continue in service and the coach should be marked sick for change of wheels in the sick lines.

Para 1009 a (i) of chg manual

NA

iii) The limits for permissible maximum flat surfaces on tread for BG ICF coaches is 50 mm (reference Rly. Bd.'s Letter no. 83/M (N)/960/1/Vol I dated 15/18.3.99)

Para 1009 a (ii) of chg manual

NA

iv) System is available for rolling – in examination at terminating station and axle box temperature is measured with non contact type temperature measuring equipment and corrective action taken for wheel sets with high temperature.

Carriage Dte/RDSO letter no. MC /AB dtd 21.08.09

NA

v) Last shop issue size (865 mm) and condemnation limit for wheel sets (845 MM) as stipulated is being followed.

NA

vii) Presently the refurbishing/overhauling of LHB bearing is being done at an interval of 1.2 million km. To ensure attention of CTRB’s as well as UST of axle, depot should have proper identification of wheels sets. In case wheel sets are interchanged then traceability of wheel sets and timely attention of wheel sets exist in the depot.

NA

viii) Depot should not permit wheel sets with NA


SN Item Clause Observation flaking in service. Adequate spare wheel sets are available in depot.

ix) Whenever coach is sent to shop for POH/IOH or non schedule attention, details of wheel sets with regard to CTRB attention should be furnished to shop. Whether system exist in depot. Similarly when loose wheel sets are sent to shop, details of wheel sets with regard to CTRB attention should be furnished to shop.

NA

x) Grease oozing out is checked during attention at depot and corrective action is taken accordingly.

NA

xi) Drain holes of control arm should be regularly cleaned to prevent its choking.

NA

xii) Checking of mounting bolts of control arm is being done during primary maintenance.

NA

31.4 Phonic wheel/Speed censor OEM guidelines

i) M8 size screw to IS 1367 Pt.III class 10.9 along with spring washer to the IS 3063 type-B should be used for securing phonic wheel. LOCTITE 243 or equivalent glue should be used to ensure rigid connection between internal and external thread. The Phonic Wheel screws should be tightened with 21N-m torque.

NA

ii) The clearance between the phonic wheel and speed sensor should be 0.9 to 1.4 mm in case of KB make WSP and 1 to 2mm in case of FTIL make WSP. This gap should be checked in quarterly schedule or whenever required.

NA

iii) The phonic wheel and speed sensor should be procured through OEMs/OEMs’ approved sources only. M/s KB and M/s FTIL are OEM of this item.

NA

iv) Speed sensors’ cables should be properly connected and should be without any loose strands.

NA

31.5 Dump Valve Proper Dump Valve connection and ensuring that no dump valve leaks during brake application.

OEM guidelines

NA

31.6 Earthing Device OEM guidelines

Earthing device of most of the coaches should be functional. It consists of non ferrous components (approx 2kg weight) which are theft prone. Loose fasteners, in case of theft attempts for non-ferrous items, mounted inside of axle box housing, can damage CTRB.

NA

Most of the earthing devices with correcting wires/cables were missing.

NA

Junction box in broken/damaged condition.

NA

31.7 Disc brake attention: OEM


SN Item Clause Observation guidelines

i) Brake pads are renewed on condition basis and adequate spare is available at depot

NA

ii) Whether regular attention of brake calliper is being ensured.

NA

iii) Whether regular attention is being given to disc brake system through AMC or in-house attention.

NA

31.8 Whether guidelines circulated by RDSO for CBC equipped coaches are being followed.

Carrg Dte/RDSO letter no. MC/BLB/CBC dtd 22.05.08

NA

31.9 Attention of side buffer:

Length of side buffer of CBC equipped SLR (FV & LV) is maintained to 635 mm as per RDSO drawing no. SK - 98145

Carrg Dte/RDSO letter no. MC/BLB/CBC dtd 17.02.08

NA


Annexure - I Standard facilities in Carriage Maintenance Depots

(Ref : CAMTECH Maintenance Manual for BG Coaches of ICF design, 1

st correction slip– CAMTECH/2002/M/C/CMM/1.0/CS-01(07.2006)

Classification of depots

Classification No. of coaches based

Minor Depot Below 100

Medium Depot 100 to 250

Major Depot Above 250

Machinery and Plant

Description Minor Depot

Medium Depot

Major Depot

Observation

U/floor wheel lath - - 1 Not available

Whiting jacks (5 Nos.) - 1 set 1 set 3

EOT crane 20T - - 1 Not available

Coach Shunter - 1 2 Not available

Welding Plant 1 2 4 10

Gas Cutting Equipment 1 2 2 3

Vacuum Exhauster 1 2 2 Not available

Air Compressor 30 cfm 1 2 2 3

Portable Vacuum Testing Equipment - 1 1 Not available

Portable Air Compressor - - 1 Not available

2T Tram beam hoist 1 1 2 2

Sewing machine - 1 1 1

Truck 10T - - 1 1

Light Coml. Vehicle 1 1 1 1

Fork lift truck - - 1 2

Lister truck 1 1 2 7

Car Washer - 1 1 Not available

Portable Trolley Light 2 4 Not available

Cotton waste soaking plant 1 1 1 Not required

Wood cutting saw machine - 1 1 2

Hand shearing machine - 1 1 1

Portable Furnace 1 1 2 1

Centre Lath - - 1 3

Bogie Manipulator - - 1 Not available

Ultrasonic Testing Apparatus 1 1 1 Not available

Tool post Grinder - 1 1 Not available

Vacuum Cleaner 1 2 3 3

Pressure Jet Cleaner 1 2 4 Not available


Description Minor Depot

Medium Depot

Major Depot

Observation

Tools

a. Pneumatic Hand Tools

i. Grinder 1 1 2 2

ii. Drill 1 1 2 Not available

iii. Chipper / Buster - 1 2 Not available

iv. Riveter - - 1 Not available

b. Electric Power Tools

i. Pop Riveting Gun - 1 1 2

ii. Drill - 1 1 20

iii. Bolt Tightner - - 1 Not available

c. Hand Tools As required Available

d. Test Bench

i. Water Tank Test Rig - 1 1 Not available

ii. D.A. Valve Test Bench - 1 1 Not required

iii. Vac. Cyl. Test Bench - 1 1 Not required

iv. Slack Adjuster Test Bench - 1 1 Not available

v. DV Test Bench - 1 1 Not available

vi. Air brake single coach test rig - 1 1 3

e. Office Equipment

i. Computer system 1 1 1 4

ii. Plain Paper Copier 1 1 2 Not available

iii. Telefax 1 1 Yes, but no phone line

Annexure - II


Emergency materials required for platform (C&W) office

Sl. Items Required Observation

1 Screw Coupling complete ( 75 t ) 1 no. 1 no.

2 Draw Hook ( ICF- Enhanced capacity) 1no. 1 no.

3 Draft cotter with 'U' pins 1no. 1 no.

4 Draft link complete 2 sets 2 sets

5 Equalizing Stay rod with pins (Non-modif. &

Modif.) 1 set each

1 sets

6 Anchor link with securing studs 1 set 1 sets

7 Truss Bar Hanger with Pins & Cotters 2 sets 2 sets

8 Bolster suspension Link (Stirrup Link) with Pins & Stones

2 sets 2 sets

9 Axle Box Face Cover (ICF) with securing nuts &

Pins 2 sets

2 sets

10 'O' Ring 2 nos. 2 nos.

11 Grease Servogen 4 kgs. 6 kgs

12 Adaptor (BF+FP) for by-passing 2 sets 2 sets

13 Angle cock 2 nos. 2 nos.

14 Dummy Flange (A/B) 2 nos. 2 nos.

15 M.U. washer 10 nos. 10 nos.

16 Teflon Tape 1 no. 1 nos.

17 Portable Air Pressure Gauge 1 no. 1 nos.

18 Pressure Gauge BP & FP 2 each 2 each

19 BP & FP Air hose 2 each 2 each

20 Guard Emergency Application Valve 2 nos. 1 no.

21 Wooden Plug (various sizes) 10 nos. 10 nos.

22 Wooden wedge 4 nos. 4 nos.

23 G.I. wire Adequ. Qt. Available

24 Buffer bolts (20x120 mm.) 8 nos. 8 nos.

25 Push cock 5 nos. 2 nos.

26 Spl. Jack for changing Eq/Stay rod 1no. 1 no.

27 Slide wrench, Pipe wrench-24'' 2 nos 2 nos.

28 Hydraulic Jacks 2 sets 2 nos.


Annexure – III Details regarding coaching depot

Depot name and division: C&W Depot, Lucknow, Lucknow Division/Northern Railway 1. Coach Holding

Mail/Expresses coaches with conventional coupling 387

Mail/Expresses coaches with CBC coupling NIL

Rajdhani/Shatabdi coaches (conv) NIL

LHB coaches (Rajdhani/Duronto) NIL

Shatabdi Coaches (conv) Nil

Shatabdi coaches (LHB) Nil

Passenger coaches 82

OCV’s 76

Grand Total 545

2. Maintenance attention of at depot

PM of Mail/Expresses train with secondary attention at other end 1 (5 rakes)

PM of Mail/Expresses train with round trip attention at other end 6

PM of passenger service with round trip attention at other end 4

Total PM attention at depot: 11

Total SM attention at depot: 4

Total Round trip attention at depot: 10

3. Pit line attention

24 coach pit with catwalk and high pressure water jet facility/watering facility at per CAMTECH’s guidelines

3 nos.

24 coach pit facility with catwalk 3 nos.

Less than 24 coach pit facility with or without catwalk (details to be collected)

NIL

Stabling line for round trip attention and stabling of rakes: Stabling line with 24 coach length facility Stabling line with less than 24 coach facility

2 nos.

NIL

Compressed air with reservoir and Air dryer/moisture trap facility with test rig (RTR)

2 nos.

Facility for welding at Yard attention 4 nos.

Night maintenance facility with overhead/pit light as per CAMTECH’s guidelines

Yes

4. Sick line facility

Coach lifting facility with overhead crane Not available

Coach lifting facility with JMP jack/hydraulic jack Hoisting jacks (each of 15 t capacity)

Total coach accommodation

With pit attention Without pit attention

(covered shed with 90m x 40m) 90 meters 210 meters

Facility for compressed air with test rig (SCTR) Available (3 nos)

Availability of hydrant water for overhead tank attention NIL

Welding facility Available


5. Facility for rolling-in/rolling-out examination with adequate lighting arrangemen (for attention

during night) as per CAMTECH’s guidelines. Inadequate/defective 6. Availability of staff for coaching maintenance as per Yard stick. Available 7. Training status of supervisor and staff – Being maintained 8. Availability of critical/ safety stores and storage system. Available 9. Availability of coaches as per rake link with maintenance spare. Available 10. Bottlenecks / limitations of system / depot. As detailed above 11. Safety performance record. Being maintained 12. Performance of critical spare. Availability is poor.

quality audit report of coaching depot bilaspur, sec...

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