draft guidelines for maintenance facilities in coaching depot on...

Government of India Ministry of Railways

Draft Guidelines for Maintenance Facilities

In Coaching Depot on IR

CAMTECH/M/GWL/MFCD/1.0

November 2014

(For official use only)

Draft Guidelines for

Maintenance Facilities

In

Coaching Depot on IR

Preface

Railway Board has issued instructions vide letter No. 2007/MC/141/1 dated

12.03.14 to CAMTECH to prepare Pre-fabricated pit line for coaching depots to

facilitate maintenance staff in doing faster and quality maintenance schedule & to

minimise maintenance cost also. During meeting for “Review of IOH/ POH

periodicity of coaches and performance review of LHB coaches” held in Railway

Board on 06.03.2014, it is decided that hand book should be prepared according to

requirement in line with DMRC and revision in M&Ps should also be done to have

full complement of tools/equipments & other machine plants in coaching depots.

These guidelines are prepared with the objective to provide informative technical

details on “Pre-Fabricated pit line without catwalk with coach washing plant” for

the guidance of Mechanical engineers involved in maintenance of Coaching stock.

It covers the constructional features of fabricated pit line, lay out drawing of pit line

without cat walk & with Automatic coach washing plant.

This Hand book does not supersede any existing instructions from Railway Board,

RDSO & Zonal Railways and the provisions of IRWM, BIS codes & reports on the

subject. This Hand Book is not statutory and contents are only for the purpose of

guidance. Most of the data & information mentioned herein are available in DMRC

and Coaching Depots on IR.

We welcome any suggestions from our readers for further improvement.

CAMTECH/Gwalior (K.P.Yadav)

Date : 25.11.2014 Director/Mech.

Contents

S.N Description Page no.

1.0 Objectives 1

2.0 New design of pre-fabricated pit line without catwalk and

with ACWP (Automatic Coach Washing Plant) 1

2.1 Merits and Demerits of catwalk 2

2.2 Covered Shed 3

2.3 Views of Railways considered for provision of catwalk 3

3.0 Twin depth pit line 4

4.0 Modern equipments 4

5.0 Other facilities 4

6.0 Coaching Depot Layout 4

7.0 Data/details of layout of coaching complex 6

8.0 Features of maintenance bay 8

9.0 Features of maintenance bay

(pit line without catwalk with shed) 9


(pit line without catwalk without shed) 10

11.0 A view of pit line at DMRC on steel pillars: 12

12.0 Maintenance bay showing ramp, stairs & pillars: 13

13.0 Service room & space for vehicle & machinery: 14

14.0 Features of IOH depot (maintenance sick line): 15

15.0 Maintenance sick-line 16

16.0

Details of infrastructure facilities proposed for

primary maintenance depot holding 500 coaches (100 AC +

400 Non AC)

17

17.0 Some modern equipments 26

18.0 Automated Wheel Diagnostic System (WDS) 26

19.0 Mobile lifting platform 30

20.0 Coach lifting system 31

21.0 Wheel changing system 32

22.0 Mechanised Laundry for Linen washing 33

23.0 Automatic Coach washing system (ACWP) 40

24.0 Layout and construction of automatic coach washing plant 42

25.0 Process of coach cleaning and washing in different stages 45

26.0 Internal coach cleaning machine 49

27.0 Justification of ACWP for coaching depots 50

28.0 Justification of coach lifting plant for coaching depots 51

29.0 Covered shed 51

30.0 Justification for all weather shed for coaching depots 52

31.0 Proposed lighting solution of coaching depots 54

32.0 Additional/Optional provisions 62

33.0 Suggestions given by zonal railways for prefab pit line and

coaching depot infrastructure during seminars. 69

ISSUE OF CORRECTION SLIPS

The correction slips to be issued in future for this handbook will be

numbered as follows:

CAMTECH/2014/C/FOUNDATION/1.0/CS. # XX date ...………….......

Where “XX” is the serial number of the concerned correction slip

(starting from 01 onwards).

CORRECTION SLIPS ISSUED

Sr. No. of

C.Slip

Date of

issue

Page no. and Item No.

modified

Remarks

CAMTECH/2014/M/MFCD/1.0 1

Hand Book on maintenance facilities in coaching depot on IR November - 2014

1.0 OBJECTIVES:

Railway Board vide their minutes of the meeting for “Review of IOH/ POH

periodicity of coaches and performance review of LHB coaches” held in

Railway Board on 06.03.2014, No. 2007/M©/141/1 dated 12.03.14 under

item “B” and S. No. 14 for performance review of LHB coaches and other

issues directed CAMTECH to evolve a design of pit line with pre-fab.

constructions for expeditious implementation of projects. In addition to this,

need to construct a catwalk should also be re-examined as pit lines without

catwalks also have advantages of more open space, easy and speedy

construction and are economical as well. This hand book is prepared to cater

all the requirements of coaching depots.

2.0 NEW DESIGN OF PRE-FABRICATED PITLINE WITHOUT

CATWALK AND WITH ACWP (AUTOMATIC COACH WASHING

PLANT

Previously a 3Tier system for coach maintenance was adopted by Indian

Railway on the basis of recommendations made by CAMTECH and

approved by Railway Board vide their letter No. 95/M©/165/11 dated

09.08.1999. In three tier system, the provision of catwalk was made for

washing/ cleaning operation of coaches during maintenance. During

finalisation of report, the provision of automatic coach washing plants at

maintenance depot was examined but, at that time, Indian Railways were

still in the process of laying these plants at few locations. It was decided

that as Railways as become fully confident with their design, performance

and sources of supply and automatic plants get proven in service, the above

arrangement may be reviewed suitably in order to explore the possibility of

having pit lines without catwalks.

In catwalk less design, for changing destination boards and window glass

cleaning, adequate number of movable trolleys/forklifts with suitable

attachment may be required. The requirement of water pipeline for coach

washing may also be reviewed in such cases.

As discussed in 12th CMG at Guwahati & CME‟s conference at Mumbai

and Shimla, it is felt by some of the Railways that the activities to be carried

out on a catwalk can be undertaken with the help of alternative means such

as mobile platforms, listers etc and therefore pit line design should be

without cat walk.

During the seminar at CAMTECH on 21.07.2014 on the issue, participants

were of the opinion that catwalk contributes little but only makes hindrance

in the free movement of man and material. Daylight is restricted and layout



makes clumsy. A new design of pit line without catwalk should, therefore,

be developed or Prefab casted catwalk with longer span may be provided.

Automated Coach Washing Plant

ACWP has been considered necessary for outside cleaning of the coaches.

This will reduce the efforts and time taken at the pitline considerably. It

will also improve the quality of the cleaning of the coaches. This will

ensure reduction in water consumption and wetness in the pitline. It has

been noticed that coach washing plants which are in use on Indian Railways

are not working properly due to various reasons. It is, therefore, proposed

that a washing plant of a specification equivalent to one available at

DMRC/PA coaching depots should be provided.

Unified Maintenance Pit-line

A unified pitline for internal cleaning of coaches/examination and repair has

been considered in place of separate facilities for internal cleaning of

coaches and repair/examination of coaches. It has been noticed that if

separate facilities are provided, the time taken in shunting is 1-2 hours and

thus the cycle time increases considerably. The very purpose of this

exercise i.e. to reduce the maintenance time gets defeated. Further, since

ACWP has been provided, the coach washing will anyway be done at the

entry point of the pitline, therefore, spillage of water on pitline will be

reduced to a great extent. This will serve the purpose of keeping the pit dry

to a great extent.

2.1 Merits and Demerits of Catwalk

SN Disadvantages of Catwalk Advantages of without Catwalk

01 Clumsy lay out Less clumsy lay out

02 Day Light is restricted Plenty of daylight id available

03 Cross movement is also

restricted

Easy movement of maintenance

staff



2.2 Covered Shed

The coaching stock examination pattern in recent years has been changed

considerably resulting into extensive utilization of coaches. A rake once

turned out from a pit line will be examined after 3500 Kms and on round

trip basis, there can not be any compromise on quality of examination and

repairs. Extreme weather conditions like heavy rains etc will make it

difficult for the staff to do a quality job in time provided for examination.

Therefore a all weather covered shed has been provided. This will ensure

proper working conditions to the staff throughout the year and will save the

staff and the stock from the vagaries of weather. In this respect comparison

was made with the existing design of structure vis-à-vis pre-engineered

buildings. It has been noticed that the pre-engineered buildings have

following features:-

Simple design and light foundations

Standard component connections

Short learning curves

Fast and standardized erection process

Low weight flexible frames offer higher resistance to seismic forces

Future expansion is simple, easy and cost effective

Lighter structure weight

The cost of pre-engineered buildings is also less in compared to conventional

design buildings, therefore pre-engineered buildings have been recommended.

2.3 Views of Railways have been considered for provision of catwalks.

Railways are sharply divided on view of this facility. While E.Rly,

S.E.Rly. strictly feels that a catwalk is must, W.Rly. and C.Rly. are of the opinion

that catwalk is not required and work can be managed with portable lifting

platform. Views of other railways were also taken.

One more design has also been evolved by CAMTECH where catwalk can be

provided only at one side of the each pit and central bay can be left for movement

of the lifting platform.

As discussed in 12th CMG at Guwahati & CME‟s conference at Mumbai and

Shimla, it is felt by some of the Railways that the activities to be carried out on a

catwalk can be undertaken with the help of alternative means such as mobile

platforms, listers etc and therefore pit line design should be without cat walk.

However some other Railways were of the view that these activities can not be



done properly without catwalk. The issue has been deliberated in detail. It is

proposed that Railways can have option from the two designs i.e.

i) No catwalk on either side

ii) Catwalk only on one side of pit line and area between two pit lines

should be without catwalk for free movement of man and material.

The details of these two designs are as per CAMTECH sketch no.3

and 4.

3.0 Twin depth pit

In the existing pit, staff can not walk without bending. Therefore, to avoid

this difficulty, it has been proposed to provide twin pit. In this design a pit

of size 600 mm wide and 450 mm deep pit has been provided in centre of

the main pit for easy walking of the staff. This will also serve as drain to

the pit as a FRP/Metallic mesh has been provided as a covered on the deep

drain for this purpose.

4.0 Modern Equipments

To improve reliability, reduce maintenance time and to have state of art,

facilities for examination, repair and maintenance of coaches, following

modern equipment have been recommended:-

Automated Wheel Diagnostic System

Mobile Lifting Platform

Bogie/Car body lifting System

Waste removal system for Bio-Toilets/Vacuum Toilets

Automatic in-motion Train Washing System

Bogie turn table.

Bio-Toilet evacuation machine

5.0 Other Facilities

Other facilities such as boundary wall, pliable road throughout the coaching

depot, concrete flooring, service rooms, proper lighting and their accessories

have also been proposed.

6.0 Coaching Depot Layout

6.1. The coaching depot is planned for 26 coach length rake.

6.2 The coaching depot consists of



a) Automatic in-motion coach washing plant (ACWP)

b) Automated wheel diagnostic system (WDS)

c) Maintenance bay (Pit-line)

d) Maintenance Sickline (under covered shed)

e) Service rooms

f) Stabling line

g) Shunting neck

6.3 Sequence of operation

(a) Train entering into the coaching depot

(b) Outside train washing on automatic in motion coach washing plant

(c) Detection of wheel defect on automated wheel diagnostic system

(e) Placement of rake on maintenance bay for complete maintenance and

safety examination

(f) Pulling the rake in shunting neck

(g) Train going out of the coaching depot after complete maintenance

Ref: Sketch-01



7.0 Data/detail of layout of Coaching Complex

77..11 (a) Length of the Coaching Complex = 2104 m

(b) Width of the Coaching Complex = 120 m

77..22 (a) Thickness of boundary wall = 23 cm

(b) Height of boundary wall = 2 m

(c) Length of boundary wall = 4000 m

7.3 (a) Width of road = 5 m

(b) Length of road = 2285 m

7.4 (a) Total track length = 6 km

(b) Number of points and crossings = 9 sets

7.5 (a) Width of the maintenance bay = 14.49 m

(b) Length of the maintenance bay = 620 m

(c) Construction of the maintenance bay = as per drawing/detail

77..66 (a) Width of maintenance Sick line = 19.5 m

(b) Length of maintenance Sick line = 200 m

(c) Construction of maintenance Sick line = as per detail

7.7 (a) Width of Service rooms = 5m

(b) Construction of Service building = as per detail

7.8 (a) Width of compressor and exhauster rooms = 5m

(b) Length of compressor and exhauster rooms = 10 m

(c) Number of rooms = 2 nos.

7.9 (a) Width of sub-station rooms = 5 m

(b) Length of sub-station room =10 m

(c) Number of sub-station room= 2 nos

Ref: Sketch-01



Prep

ared

By

Sket

ch N

o. 1

CA

MTE

CH

/Gw

alio

r




8.1 Data/dimensions :

(a) Length of maintenance bay = 620 metres

(b) Width of maintenance bay = 14.49 metres

(c) Capacity = 2 rakes

8.2 The maintenance bay is meant for all safety checks, schedule and non

schedule maintenance of under gear and upper gear.

8.3. Main features of the maintenance bay are -

a. Broad and obstacle free pathways.

b. Under pit pathway below the rake/track.

c. Pit line on metallic (steel) pillars.

d. Ramp at both the sides to go from ground level to pathways.

e. Provision of stairs to go from ground level to pit pathway.

f. Provision of service rooms.

g. Provision of mobile lifting platform (for without catwalk).

h. Provision of compressed air pipe line.

i. Provision of overhead light.

j. Provision of under pit light.

k. Provision of 48V,110V, 230V ,440V cables and sockets

8.4 Other salient features:

a. The covered shed is having zig-zag placement of sufficient number of

transparent sheet for sufficient natural light during day time.

b. To make the pathways obstacle free cables for the sockets are running

underground.

c. The under pit light are located such that they come under each bogie

of each coach.

NB : 1. The sketch of maintenance bay does not have structural and

foundation design of load bearing items.

2. Hence the dimensions shown may require changes due to design

considerations.



9.0 Features of maintenance bay (pit-line without catwalk with shed)

9.1. Data/dimensions :




PIT LINE WITHOUT CAT-WALK

2500

960

e

325

960

C250

850

400

600

1250

4503000

a

40

25

d

3245

d d

1300785

2500

960

e

Prepared by CAMTECH Gwalior

Sketch No. 2

3245

d

b

2 m

a

5 m

Ground Level

3 m

Drain

Note : The pit line is proposed on steel pillars of 500x500 size with a clear space

of 1000 mm between the pillars. The detail drawing to be prepared by the

Zonal Railways based on actual site conditions and necessity of loco

movement.



10.0 Features of maintenance bay (pit-line without catwalk without shed)

10.1. Data/dimensions :






10.2 Features of maintenance bay (pit-line with side catwalk)

1. Data/dimensions :




Covering features of both pitline with catwalk and without catwalk

Note :The pitline is proposed on steel pillars of 500x500 size with a clear space of

1000 mm between the pillars. The detail drawing to be prepared by the Zonal

Railways based on actual site conditions and necessity of loco movement.



11.0 A view of Pit line at DMRC on steel pillars:

Pit line at DMRC



12.0 Maintenance bay showing ramp, stairs & pillars:

Sket

ch N

o. 4

Prep

ared

By

CA

MT

EC

H/G

wal

ior



13.0 Service Room & Space for Vehicle & machinery:

3. A

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oms a

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tted

with

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INER

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Exam

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ion

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Veh

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2. A

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and

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Sket

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14.0 Features of IOH Depot (Maintenance Sick Line):

1. Data/dimensions :

(i) Length of maintenance sick line = 200 metres

(ii) Width of maintenance sick line = 19.5 metres

(iii) Capacity = 2 lines

2. The IOH Depot (maintenance sick line) is meant for attending the unfit

coaches and for attending higher maintenance schedules of the coaches.

3. Main features of the maintenance sick line are:

a. Provision of 04 coach length examination pit – one on each line.

b. Provision of wheel profile lathe.

c. Provision of bogie/coach lifting system.

d. Provision of equipments like coach lifting jacks, material carrier,

fork lifter, hoist, bogie turn table.

e. Provision of service rooms, store and vehicle parking space.

f. Provision of wheel parking.

g. Provision of covered shed.

h. Provisions of electrical fitting, light, fan etc and electric supply to all

fixed and portable machines and equipments

NB : 1) The sketch of maintenance sickline does not have structural and

foundation design of load bearing items.

2) Hence the dimensions shown may require minor changes due to

design considerations.

3) Big machineries like wheel lathe, coach lifting system etc should be

installed suitably.

Ref: Sketch No. 05 & 06



15.0 Maintenance Sick-line:

CAM

TECH

/Gwa

lior

Prep

ared

By

Sketc

h No.

6



16.0 DETAILS OF INFRASTRUCTURE FACILITIES PROPOSED FOR

PRIMARY MAINTENANCE DEPOT HOLDING 500 COACHES

(100 AC + 400 NON AC)

16.1. INFRASTRUCTURE & BUILDING

S.N. ITEM COACH

HOLDING

500(100 AC +

400 NON AC)

1. Covered shed (sick line ) 1

2. Maintenance lines with pit

(No. of lines X No. of coaches) 2 x 4

3. Linen store room, size 5 m x 10 m 2

4. Room for storing cleaning equipment, size 5 m x 10 m 1

5. Mech. Item repair room with test benches, size 5m x 8

m (DV, brake cylinder, CDTS etc) 4

6. Mechanical millwright room, size 5 m x 8 m 1

7. Computer room, size 5 m x 5 m 1

8. Battery room with battery beds, size 5m x 10m 2

9. Fans repair room, size 5 m x 10 m 1

10. Light fittings repair room, size 5m x 10m 1

11. Alternator/ regulator repair cum testing room, size 5m

x 10 m 2

12. Compressor repair room with AC cabin, size 5m x 5m 1

13. Switch gear test room with shelves and test benches/

work benches, size 5 m x 8 m 1

14. Motors repair room with shelves and test

benches/work benches, size 5 m x 8 m. 1

15. Simulator training room for RMPU, inverter & power

panel, size 5 m x 10 m. 1

16. Filter cleaning arrangements with blower & water

sump size 5m x 5m 1

17. Tool room with shelves & almirahs, size 5 m x 8 m. 2



S.N. ITEM COACH

HOLDING

500(100 AC +

400 NON AC)

18. Storing facility for Lube, HSD, Kerosene oil, size 5m

x 5m. 1

19. Storing facility for refrigerants, DA, Oxygen, Nitrogen

cylinders, size 5 m x 5 m. 1

20. Pantry equipment repair room, size 5 m x 5 m. 1

21. Depot Officer room (Gazetted) , size 5 m x 5 m. 1

22. Incharge/ Supervisors office , size 5 m x 5 m. 4

23. Establishment office, size 5 m x 10 m 1

24. PPIO office, size 5 m x 5 m. 1

25. Material management office, size 5 m x 5 m. 1

26. Main store with Unit Exchange Spares and material

storing facilities size 5 m x 10 m. 3

27. Shift/ Custody stores with material storage facilities,

size 5 m x 5 m. 2

28. Conference room of size 5 m x 10 m. 1

29. Staff room with lockers, size 5 m x 8 m. 2

30. Staff room for ladies size 5 m x 5 m 1

31. Electronic lab (AC) with all repair and testing

facilities, size 5 m x 5 m 1

32. Staff training room facilities including Multimedia

projector, LCDTV, video camera, DVD Handycam &

other modern teaching aids, size 5 m x 8 m.

1

33. Vehicle repair room, size 5 m x 8 m. 1

34. Staff Canteen of size 5 m x 20 m. 1

35. Mechanised Laundry for linen washing on BOOT

model

1 Unit

36. Bio-Toilet Evacuation Machine 1



16.2 OTHER INFRASTRUCTURE

S.N. ITEM COACH

HOLDING

500(100 AC +

400 NON AC)

1. Scrap material space of adequate size 1

2. Scooter & cycle stand 1

3. Separate toilets for ladies & gents at suitable

locations

4

4. Garage pickup van/ material van 2

16.3 MMAACCHHIINNEE && PPLLAANNTT ((MMeecchhaanniiccaall))

S.N. ITEM COACH

HOLDING

500(100 AC +

400 NON AC)

1. Automatic coach washing plant (ACWP) 1

2. Wheel diagnostic system (WDS) 1

3. Coach lifting system 1

4. Wheel profile lathe 1

5. Hydraulic lifting jack/Whiting Jacks 6

6. Welding plant (portable) Single phase 230 V 4

7. Welding plant (Stationary) 3 Ph. 440 V 2

8. Air compressor-350 cfm 2

9. EOT crane 5T in maintenance sick line 2

10. Floor scrubber 10

11. Dry & wet vacuum cleaner 10

12. Mobile jet cleaner 10

13. Drainage pump heavy duty 5HP (Muck pump

centrifugal) 2

14. Sewing machine 1

15. Portable pump 2

16. Gas welding-cutting set 4

17. Lathe machine, 1000mm between center complete 1



S.N. ITEM COACH

HOLDING

500(100 AC +

400 NON AC)

including spares and accessories with attachment

for precision grinding and tapering.

18. Bench vice 4

19. Medium sized electric motor driven pillar drilling

machine complete.

2

20. Heavy-duty motor driven pedestal grinder

complete.

2

21. Portable electric motor driven drill machine. 4

22. Portable electric motor driven grinder. 2

23. Electric motor driven Winching machine for

movement of coaches of suitable capacity

2

24. 46.7 Ltrs spare oxygen (7 m3 ) cylinders 4

25. 41 Ltrs spare Acetylene (5.5 m3 ) gas cylinders 4

26.

Hand tools for mechanical staff

As per

requirement

27. Maintenance staff tool boxes with tools. For each

technician

16.4 MACHINE & PLANT (Electrical)

S.N. ITEM COACH

HOLDING

500(100 AC +

400 NON AC)

1. Distilled water plant – preferably solar system, (in

ltrs per day) 2 x 100 lpd

2. Condenser cleaning tank 1

3. Hydraulic operated scissor – type platform truck of

1Tonne capacity.

4

4. Vacuum pump with gauges etc. 2

5. Battery charger sets 110V, 300A DC 3

6. Portable battery charger input 230 V single phase,

output 110V, 40A DC

2



S.N. ITEM COACH

HOLDING

500(100 AC +

400 NON AC)

7. Battery charging/ pre cooling sockets with

universal type connector

At each coach

length

8. Constant current constant voltage battery charger

upto 10 cells.

1


upto 12 cells

2


upto 56 cells.

2

11. Constant current discharger. 2

12. Battery analyzer 2

13. Air quality measurement facility 2

14. Dynamic balancing machine for balancing of fans,

shafts & alternator pulley

1

15. Hydraulic puller of 10T capacity 2

16. Escorting staff tool boxes with tools. (As per

RDSO)

For each

escorting staff

17. Maintenance staff tool boxes with tools. (As per

RDSO)

For each

technician

18. Motorised Megger 500, 1000V. 4

19. Refrigerant recovery plant. 1

20. Electronic weighing machine upto 15kg 2

21. Electronic weighing machine upto 50 kg 3

22. Electronic weighing machine upto 500 kg 1

23. Ordinary tool set for tool room (Torque wrenches,

special spanner, soldering iron, manual cable

crimping tool, hydraulic crimping tool, cable

stripper, cable cutter, pliers, screw drivers, line

tester, cell tester, test lamp, hammers, mallets,

riveting tool, punching tool)

15

24. Measuring tool set for tool room (dial indicators, 15



S.N. ITEM COACH

HOLDING

500(100 AC +

400 NON AC)

feeler gauge sets, vernier calipers, vernier

micrometers, torque wrench, depth gauges, screws

gauge, Go/No Go gauges, Hydrometer)

25. Special tools for AC for tool room (Refrigerant gas

leak detector, Tube cutters, pinch off tool flaring

tool, charging line, hand shut off valves,

combination gauge, air flow meter, Contact less

thermometer, LP gauge, HP gauge, tube bender,

lapping machine)

10

26. Electrical testing tools for tool room (Digital multi

meters, industrial grade AC & DC ammeter, digital

tongue tester, insulation megger tester, contact less

thermometer, digital thermometer, Anemometer,

hygrometer, lux meter)

15

27. Testing benches comprising following equipment

variable voltage supply AC & DC, transistor tester,

meter testing kit,

2

28. V-belt pre stretching machine (grading machine). 4

29. Portable electric motor driven blower 6

30. 46.7 Ltrs spare Nitrogen (7 m3 ) gas cylinders 4

31. Spare R-134a refrigerant cylinders 6

32. Digital dB. Meter (noise level indicator) 1

33. Oven for drying electrical machines etc. of suitable

size.

1

34. DG set, with canopy 415V of adequate capacity as

standby power supply

1

35. Shock pulse meter 3

36. Tachometer 1

37. Platform jack for handling alternators on the

coaches

2

38. Grease gun for lubricating equipments 1



16.5 TESTING FACILITIES (Electrical)

S.N. ITEM COACH

HOLDING

500(100 AC +

400 NON AC)

1. Pit mounted 25 kW AC test drive complete set (2

unit per set) for alternator and regulator testing.

1

2. Floor mounted 25 kW AC test drive complete set

with regenerative load testing for alternator and

regulator testing.

2

3. Test benches for testing relays & contactors with

contacts testing.

1

4. 1kW Portable motor drive set for testing alternator

and regulator.

3

5. Power supply analyzer, oscilloscope dual channel,

storage type

1

6. Surge comparison tester for testing windings of

motor

1

7. Inverter testing facility 1

8. Inverter card reading & repairing facilities 1

9. WRA/ Mono-block pump testing facility 1

10. Spring testing facility for testing of alternator spring 1

11. Test bench for repairing RRU, ERRU and

alternators

2

12. ERRU testing facility all make 1

16.6 TESTING FACILITIES (Mechanical)

S.N. ITEM COACH

HOLDING

500(100 AC +

400 NON AC)

1. Air brake rake test rig 2

2. Single car test rig (SCTR) 2

3. Water tank test rig 1

4. Ultrasonic testing apparatus 1



5. DV test bench 1

6. SAB test bench 1

7. Test bench for CDTS/Bio-Toilet 1

16.7 MATERIAL HANDLING EQUIPMENTS

S.N. ITEM COACH

HOLDING

500(100 AC + 400

NON AC)

1. Fork lifter 3T 2

2. Fork lifter 1.5T 2

3. Lister 1.5T 6

4. Mobile lifting platform 10

5. Hydraulic pallet truck 01T capacity 4

6. Lorry truck 1

7. Pick up Van 2

8. Push type/ Hand trolley 500 kg 6

9. Material van 2

10. Garbage picking tongs for Bio-Toilets 1Set

11. Tool Bag for maintenance of Evacuation

machine 1 Set



16.8 SAFETY EQUIPMENTS

S.N. ITEM COACH

HOLDING

500(100 SG AC +

400 NON AC)

1. All workmen safety equipments such as industrial

helmets, hand gloves, industrial shoes, masks,

minor lamp etc.

As per

requirement

2. Fire extinguishers, water hydrants, sand buckets

with stand

As per

requirement

3. Safety belts As per

requirement

4. FFiirrsstt aaiidd bbooxxeess As per

requirement

16.9 ADDITIONAL

S.N. ITEM COACH

HOLDING

500(100 AC +

400 NON AC)

1. Computer (PC) with printers with LAN facility. As per

requirement

2. Fax Machine 1

3. Zerox Machine 2

4. Walkie talkie sets/ Mobile sets/P &T phones/

intercom and other communication facilities

As per

requirement

5. Water Cooler As per

requirement

6.

Storage racks, almirah, locker, furniture etc

As per

requirement

7.

Bins, container etc

As per

requirement

NOTE: Facilities for the items which are likely to be offloaded to trade

should be provided judiciously to avoid wastage of resources.



17.0 SOME MODERN EQUIPMENTS

a. Automated Wheel Diagnostic System (WDS)

b. Automatic in motion Train Washing System

c. Mobile Lifting Platform

d. Bogie/Car body lifting system

e. Under floor bogie repair hoist

f. Turn table

g. Waste removal system for Bio-Toilet

h. Evacuation machine for Bio-Toilet Tanks

18.0 Automated Wheel Diagnostic System

A- DDeessccrriippttiioonn:: Wheel Diagnostic System is a fully automatic and in

motion inspection and testing unit for the diagnosis of wheels of

vehicles in operation.

B- Wheel diagnostic system aims at the following types of diagnostic

work :-

a. Vehicle/wheel set identification

b. Measurement of roundness of wheel and detection of value of

out of roundness

c. Detection and measurement of flat spots

d. Measurement of tread diameter and detection of overshooting

of operational tolerances

e. Measurement of wheel profile and detection of overshooting of

operational tolerances

f. Detection of cracks

Probable source: 1. Hegenscheidt –MFD GmbH & Co Kg

P.O. Box 1652-D-41806 Erkelenz

Website : www.hegenscheidt-mfd.de

Fax- 0049(0) 2431 86 470

Indian agent : M/s VGI Power Systems(P) Ltd.

16-A, Palam Marg, Vasant Vihar

New Delhi-110057

Contact person (India): 1. Mr. Jaspreet Singh

Mobile no. 09810421620

2. SAB Wabco

Cost : Rs.5.0 Crores

http://www.hegenscheidt-mfd.de/



18.1 Technology:

A. Wheel diameter/wheel profile measurement (laser based)

The moment wheel passes over the rail, a beam of light is passed on to

the wheel from under it. The emerging rays are received by a receiver

and fed to a computer which evaluates the inputs. By using Opto-

electrical equipments and high resolution digital cameras and

computers which are capable of accurately processing the digital

data, the wheel profile measurement can be performed.

BB.. DDeetteeccttiioonn ooff ffllaatt aarreeaass && oouutt ooff rroouunndd

Along a stretch of track equal to the circumference of the wheel, distance

between the track and the wheel crown is continuously measured

electronically and evaluated by a computer. The flat areas are detected by

the variations of height between track and the wheel crown. The difference

between largest and smallest diameter will give the measurement of

out of round.

CC.. CCrraacckk ddeetteeccttiioonn

Two ultrasonic scanning heads each are integrated in the left and right rail

of the track, when a wheel passes through the scanning heads, this transmits

ultrasonic impulse for the detection of the cracks on the tread surfaces.

By providing wheel diagnostic system, it will pre-warn the condition of

wheels. This will help in -

Average planning of wheel profiling and wheel change.

Improved safety and reliability

Improved wheel life.

Reduction in examination time and manpower.

Based on above benefits the provision of wheel diagnostic system is justified.

(Photograph on next page)



18.2 Photograph of Wheel Diagnostic System

18.3 Layout of Wheel Condition Monitoring System

Inrail installed wheelset diagnostic system

Wheel Condition Monitoring System •

Identi - fication

roundness and

flat spot

basic module

diameter cracks profile and

back to back

database

Remote access

Data exchange

Inrail I nstalled wheelset diagnostic system

Wheel Condition Monitoring System •

Identi - fication

roundness and

flat spot

basic module

diameter cracks profile and

back to back

database

Remote access

Data exchange

In Rail Installed Wheel Set Diagnostic System



Under Floor Wheel Tyre Turning Machine

under floor wheel lathe machine should be provided in medium & major capacity

coaching depots (coach holding up to ……) the specification and accessories may

be provided in line with DMRC/Depot. The photo of machine with make is as

under-

Photo of Atlas Rail wheel lathe machine



19.0 Mobile Lifting Platform

(Aerial work lift platform)

Description : Battery powered aerial work lift platform with hydraulically

operated scissor lifts.

Source of supply : 1. JLG Industries Inc

1- JLG Drive,McConnellsburg,PA, USA

Contact person (India): Mr.Sunil Jain Reg.Mgr

Mobile no. 09810119569.

2. NeueroTechnologies GmbH, Germany

Cost : Rs.15 Lakhs



20.0 Coach lifting system

Description : Coach lifting system with under floor lifting plant and car

body stand.

Source of supply : 1. Neuero Technologies GmbH

Germany

Indian agent : M/s LAN Railtech. Pvt. Ltd.

K-1/81, C.R. Park, Ist floor

New Delhi-110019 Tel. 011-26271369, 26276449

Contact person : Mr.O.N.Jalota Jt.Managing Director

Mobile no. 09810158226

2. M/s Pfaff

D-86316, Friedberg/Derching,Germany


Lifting Jacks: 1. Jamalpur Workshop, Jamalpur

20.1 Photograph of Coach Lifting System



21.0 Wheel changing system

Description: Elevated track with split rail bridges and wheel set changer

Source of supply : 1. Neuero Technology

Germany

Indian agent : M/s LAN Railtech.Pvt.Ltd.

K-1/81, C.R.Park, Ist floor

New Delhi-110019 Tel. 011-26271369,26276449

Contact person : Mr. O. N. Jalota, Jt. Managing Director

Mobile no. 09810158226

2. Windhoff, Germany


21.1 Photograph of Wheel changing system



22.0 Mechanised Laundry for Linen washing:-

Description: As per Railway Board‟s letter No. 2009/M(C)/165/6 dated

04.07.2012, setting up of Mechanised laundry has now been permitted through

licensing of Railway land. Revised model guidelines for setting up of mechanised

laundry for washing of linen on BOOT model alongwith railway land license

agreement are also attached with the details for implementation.

Where the daily requirement of washed linen is high say 07 tones or above,

the batch washer system (Tunnel washer system) may be considered by the

Railways.

Source of supply:

1. M/s GIABAU Germany.

2. M/s STEFAB India Ltd., West Punjabi bagh, New delhi, Pin-110026

Phone No. 011-41018201, Fax 011-41018207/08.

Batch Pass-Through Dryers

Batch Washer

Flat Work IRONER –PSN-80



Details of Basic components of Automated laundry Machines/equipments to

be supplied, installed and operated by Tenderer –

A. Smaller Capacity Laundries: a. Washer cum extractor

b. Tumbler drier

c. Flat bed ironer/Calendaring machine

B. Batch Washer Systems [Tunnel type]

Washing System: Capable to handle large volume of linen optimizing, water,

electric power, steam and chemicals

- All parts should be of SS 304 or superior.

- Computer controlled system.

- Automatic dosing of chemicals

Pressing System:-

- System should be equipped with a hydraulic press for water extraction.

- Extracted water should be re-used in the batch washer.

- All components should be of SS- 304.

Drying System:- - System should be fitted with large capacity of pass-through dryers.

- System should avoid bunching of the linen at one end of the drier drums.

- The drier drums should have Teflon coating of the interior.

- Sprinkler should be provided when temperature exceeds set limit.

- The dryers should have an automatic lint cleaning system.

Ironing System:- - Sufficient Flat-work Ironers to be fitted.

- Ironers (Calendering machines) should have micro-processor-based variable

speed.

Term of concession agreement:-

- Commissioning of the laundry must be ensured within 2/5 months from the

issue of LOA.

- Contract for setting up of an automated laundry on a BOOT scheme shall be

for a period of 10 years (for smaller capacity laundries)

- Contract for batch or Tunnel type washer system for a period of 15 years.

- After commissioning, the ownership of all machines and plants shall be

transferred to Railways in good working conditions without any extra

cost/charge.

- the laundry shall be used by contractor for Railways work only.



Electricity:-

Railways may supply electricity for operation of the mechanized laundry, up to

the limit quoted by the tenderer.

Contractors Responsibility:-

1. Will be responsible for new procurement and commissioning of laundry

equipments.

2. Shall ensure that all effluents from the mechanized laundry conform to

pollution control and other limits.

3. Shall furnish a certificate, valid upto the period of completion of contract for

proposed machines and warranty, AMC etc.

4. Operation of Laundry by skilled technical staff, trained by the OEM.

5. Must follow all labour laws.

6. Shall also provided adequate facility for storage of washed and packed linen

sets in racks made by SS.

7. Use of water proof bags.

Contractors scope of work for linen management.

- Collection of used/soiled linen from AC coach attendants.

- Transportation to the laundry stores.

- Removal of tough stains caused by spillage of food & misuse etc.

- Washing, drying, calendaring, ironing in the automated laundry.

- Packing of linen sets in bags and storage.

- Supply and loading of washed linen sets to attendants in the AC coaches at

platforms washing lines.

- Maintaining proper accountal of linen items.

Quality of cleaning of linen:

- The average whiteness of new linen items after 5 washes shall be taken as

the base reference i.e an index of 100% .

- The contractor must ensure at all the times a minimum whiteness index of

75%.

- The tenderer should also provided instrument for checking whiteness.

- There should be no wrinkles or wetness after calendering.

- The washed linen should be hygienic bacteria free, stain free and odour less.

- To be ensured that the washing procedures and cleaning agents used render

a minimum prescribed service life for new linen items.

01 year for Khadi bed sheets of ACASH

02 years for Poly-vastra bed sheets of KVIC.



Inventory of washed bed rolls:-

- Contractor must make sure that used linen as unloaded from the trains, must be

washed and made available for train services within 48 hours.

- Contractor shall ensure enough “buffer stock” to cater the requirements of at

least 2 to 3 days.

Inspection/Audit check of washed linen:

- Test checks may be ensured on the washed linen kits in conformity with the

guidelines issues in terms of SN- 2 of para 2.1 of Board's letter dated 04

.01.2010.

- During sampling checks if poor quality detected, a penalty of Rs. 3/- per items

may be imposed apart from non- payment.

- In the event of rejection of more than 2% on account of poor washing, the

quantity of that particular lot of linen shall have to be washed again.

- Monthly report of summary of· all inspections/ test checks carried by Officers.

Penalties for unsatisfactory performance:-

1- For non commissioning of Mechanized laundry within 2/5 months from

LOA, LD as per GEC.

2- Rs. 0.50 per item of linen held in excess with contractor.

3- Cost of linen items lost /damaged by contractor to be recovered as per rates

circulated by Railway authorities.

4- In the event of Passenger complaints a penalty of Rs.2,000/- per occasion.

5- In the event of Non- packaging of linen, a penalty of Rs. 1.0/- per packet.

6- n the event of the soiled/used linen not unloaded from the incoming trains,

and fresh linen not loaded a penalty of Rs. 5,000/- per occasion may be

imposed.

7- Penalty up to Rs. 1,000/- per occasion may be imposed for non-Adherence

Contractual conditions.

Passenger Feed Back

1. Passenger satisfaction and feedback is the essence of the linen services.

2. Contractor shall make arrangements for making feedback forms available to

the passengers through AC attendants/ACCI.

3. AC attendants/ACCI shall obtain passenger feedback from atleast 5

passengers per AC coach in each direction.

4. One feed back shall also be taken from Ts/TTE for each direction.

5. Penalty for unsatisfactory work may also be based on the passenger feed

back.



Format for Passenger feed back

WASHED LINEN IN THIS TRAIN IS PROVIDED BY THE AUTOMATED

LAUNDRY SET UP BY M/S_____(NAME OF CONTRACTOR/FIRM AND

TELEPHONE NO.)

Dear Passenger,

Our endeavor is to provide you hygienic linen services. Your valuable feedback

would help us improve further.

Kindly spare few minutes in rating the areas as given in table below:-

Ratings:

5=Excellent, 4=Very Good, 3=Good, 2= Average, 1= Poor

Passenger Feedback- AC Coaches

SN Areas of Service 5 4 3 2 1

Please mark( ) in space

1 Cleaning/Whiteness of Linen

2 Dryness of Linen

3 Ironing & Packing

Passenger Name:

Train No:

Coach No.:

PNR No:

Date of Journy:

Telephone No: Signature of Passenger



Laundry shall be built and operated on BOOT (Build –Own-Operate-Transfer)

Specifications of the Linen:-

S.N Item Specification Existing

Codal Life

(Months)

Suggested

Codal life

(months)

1 Bed sheet Handloom cotton Bed

sheet bleached, size

140X229 cms,

12

2 Bed Sheet Poly vastra size

140X229 cms

24

3 Bath Towels Turkish size 81.3X152

cms

9

4 Hand Towel Hand Towel Turkish,

cotton, superior

quality, Size 40X60

cms,

9

5 Pillow Cover White Pillow cover

handloom, size 32X62

cms with 3 cms wide

boarder or all sides

9

6 Pillow cover Poly vastra 69X46

cms.

12

7 Pillow Size 50X36X10 cms. 24

8 Pillow big size Size 60X36X12 cms. 24

9 Blanket Size 229X140 cms. 48

10 Blanket for AC-I Size 230X152 cms. 48

B-Proposed outlines for linen management:-

1. Complement of linen to be provided in coaches.

2. Specifications of linen items.

3. Managerial control over linen.

4. Infrastructure required for linen management.

5. Infrastructure of mechanized laundry.

6. Machine/Plants required at laundry..

7. Transportation of linen.

8. Stock and Storage of linen.

9. Tendering system for out-sourcing & Tender schedule.

10. Sample test check of linen items.

11. Condemnation of linen.

12. Packing of linen.



13. Permitted quantity of linen with contractor.

14. Various penalties on contractor for linen.

15. Whiteness checking equipment for bed sheets.

16. Daily Position Performa.

17. Monthly Position Performa.

18. Computer programming for stock.

19. Transportation bags for linen items.

20. Likely Sources for linen procurement.

21. Instructions for linen distribution agency i.e. AC/attendants.

22. Existing guidelines/letters circulated by Railway Board.

23. Work distribution among linen cell staff i.e. SSE, JE, Tech. & Clerks.

24. Nomination of officers for control over linen management.



23.0 Automatic Coach washing Plant (ACWP)

Description : Automatic in-motion coach/train washing plant for exterior,

roof and under carriage cleaning with high pressure cleaning jet and with

vertical and horizontal rotating brushing unit .

Source of supply : 1. M/s Wesurail - US

2. M/s Bingham - UK

Cost : Rs.400/- lakhs

23.1 Photograph of Automatic in motion train washing system

Cleaning of coaches is the problem of the entire Indian Railways. Washing

and cleaning of coaches is one of the though and critical jobs to be carried

during train examination. The train movement on the such dusty/sultry

climate of the region, to ensure desired level of cleanliness of coaches of

Railways passenger trains is a real challenge. The rakes of these trains are

examined and maintained at C&W Depot During examination of these

rakes, internal and external cleaning and washing of coaches is being

carried out. It is observed and studied that oily & sticky smoke emitted by

Diesel Locos especially in tunnels result in sticky soot and stains being

formed on the coaches thus resulting in a real problem of cleanliness of the

coaches and this has attracted public criticism also. As the staff is limited,



the desired level of cleanliness cannot be done satisfactorily by

conventional method within limited time period.

23.2 AUTOMATIC COACH WASHING PLANT

To overcome the above problem of coach cleanliness, a method of external

cleaning of coaches by high-pressure water jet pump was adopted earlier.

Seeing at number of staff involvement in carrying out coach cleaning, coach

washing plant is developed by CAMTECH. In this plant, external cleaning

of coaches of a rake was done at NGP, Madgaon & Kurla by horizontal

rotating nylon brushes while passing through.

Eight powered nylon brushes were provided in this plant for the purpose of

rubbing of soap solution and cleaning of dirt on external surface of coach .

1.Stages of

a) Pre-wash,

b) Spraying of pressurized soap solution mixed with compressed air.

c) After wash with high-pressure water jet were developed and

incorporated in this washing plant.

In addition to horizontal nylon brushes, two Coir brush fixtures were

developed and fitted in this plant. These coir brushes were static (non-

rotating type) and fixed in one position for the purpose of even application

and rubbing of soap solution on surface of coach, thereby sticky particles of

soot and dirt get loosened and removed. But this coir brush could not touch

and clean the area near window-sills, upper and lower portions of coach

since upper portion of coir brush was obstructed by coach indication lamp,

indication board, destination board and lower curved portion (turn under) of

coach due to less stiffness of coir brush. Hence these portions were used

to be cleaned manually by available staff.

This plant is developed with keeping in view the following points in mind.

a) Less and economical maintenance of the modified washing plant.

b) Less manpower requirement for operation and maintenance this plant.

c) 95% exterior cleaning of a entire rake of 24 coaches is to be achieved

within 35-40 minutes.

d) Reduction in water and soap solution consumption compared to the

conventional Manual coach cleaning.

e) Reduction in power consumption by using automation.

f) Cleaning and disinfection of underneath portion of toilet by High

pressure jets.

g) Bogie side cleaning by high pressure jets.

h) Roof cleaning of Coach by horizontal nylon brush.



24.0 LAYOUT AND CONSTRUCTION OF AUTOMATIC COACH

WASHING PLANT

The modified coach washing plant is situated at the entry point of rake

examination pit at coaching depot. There are four fabricated structures in

this washing plant.

1) First structure is having plan

area of 17sq.mtr. (5mX 3.4m)

and provided for PREWASH

stage. This structure is erected

at a distance of 30 meter from

second structure, to get

complete soaking of coach

with water.

2) Second structure is having

plan area of 8.16 sq.mtr.(2.4m

X 3.4m), is made from 300 x

150 mm ISBM & 300 x 90

mm „C‟ channel This

structure is provided for the

stages of SPRAYING OF

SOAP SOLUTION and

Rubbing Of Soap Solution by

vertical nylon brushes.

3) Third structure of underneath

pipelines along with air and

water reservoirs having plan

area of (4.5mX3.4m)

15.3sq.mtr. and it is provided

at distance of 16mtr. from

second structure. This

structure is provided for stages of UNDERNEATH TOILET PORTION and BOGIE CLEANING.



4) Fourth structure is having plan area of

48 sq.m.(14m X 3.4m) and provided

for the stages of a) Moistening of soap

solution b) Roof cleaning by a

horizontal nylon brush c)Side cleaning

by four vertical cotton brushes. d)

After wash with high pressure jets.

e)Mopping by two vertical cotton

brushes. and Fourth structure is

erected at distance of 23 mtr. from

second structure, to get sufficient time

for reaction and complete soaking

with soap solution. near washing

plant.

This structure is located at start of pit line

is aligned and extended to old existing

structure of coach washing plant. It is

also made from same material used for

second structure. Central apron already

exists between the structure & track. It is

provided with proper drainage and

concrete apron in between structure and

track and nearby area at all above

locations so that waste water and soap

solution will drain out immediately to

adjacent main drainage and avoid

adverse effect on sleepers and track. Due

to proper apron and drainage,

accumulated dirt and waste are easily

cleaned and maintained with hygienic

condition.

OLD STRUCTURE OF PLANT

RENOVATED STRUCTURE

OF COACH WASHING

PLANT



Water is supplied from overhead tank of 40000 ltrs. capacity to underground tank

of 10000 liters capacity (shown in figure). Water from under ground tank is

supplied to coach washing plant for Pre wash and After wash stages, by 3 HP

pump along with stand by, are located inside pump house. Soap solution is made

in overhead plastic tank of 1000 ltrs. and this soap solution is supplied to coach

washing plant for Spraying of solution stage, by one HP pump. Water pipe

connections for Pre wash , After wash , Toilet and Bogie cleaning stages are made

from 1" and 2" pipes and soap solution pipe connection is from 1" pipe. Electrical

switchgears and control panel are provided for 3 Pumps (1 for soap solution and 2

for water),motors (each 3 hp)of 1 horizontal nylon roof cleaning brush and 6

vertical cotton brushes and 2 vertical nylon brushes for soap solution rubbing, in

the pump house which is located near to washing plant. Compressed air supply,

which is already available at pit line, is tapped for soap solution spray.

Both structures and vertical brush unit have been painted with two coats of epoxy

primer and paint. Since this Iron structure and sub assemblies are more prone to

corrosion due to existing salty weather and acidic/alkaline soap solution used in

washing plant, epoxy painting is one of the better options to reduce corrosion and

the cost.



25.0 PROCESS OF COACH CLEANING AND WASHING IN DIFFERENT

STAGES

25.1. PRE-WASH: A rake is moving at speed of 5 KMPH during cleaning

and washing of coaches through this plant. In this stage a diffuser type

sensor is provided for sensing coaches of a rake. As soon as this sensor

senses first coach of a rake, water starts spraying on external surface of

coach through number of holes provided on water pipelines erected around

in a row.

25.2. SPRAYING OF SOAP SOLUTION: In this stage, diluted soap

solution is sprayed on coach surfaces including two sides and roof through

seven sprinklers. Provision is made for mixing of compressed air with

pressurized soap solution inside the sprinklers to get more bubbles formed

when it strikes with coach surface.

Two sides and roof of

coaches are completely

wetted by low velocity

sprinklers at this stage,

some loose dust & dirt is

washed away from coach

surface and

simultaneously, coach

surface is made uniformly

wet, which help in even

application of soap

solution on coach body.

Due to release of surface tension in

bubbles, dirt particles are loosened

and washed away easily. Flow and

quantity of soap solution can be

controlled and adjusted by operating

spindle nut on sprinkler and both

valves provided on soap solution

line and pneumatic line.



25.4. SOAKING OF SOAP SOLUTION:

In this stage, soap solution is allowed to soak completely for approx.1

minute in normal washing process. This stage is automatically achieved

while rake is moving at 5 Km/h. through coach washing plant, since stage 3

and stage 5 is kept apart at 30 meter distance. During this stage, soap

solution, is chemically reacted with dirt.

25.5. MOISTENING OF SOAP SOLUTION:

In this stage, moistening of partially dried soap solution is carried out by

sprinkling of very low-pressure water through number of nozzles provided

on a water pipe line. Hence soap solution applied on roof and sides of

coach become wet before rubbing by horizontal and vertical brushes.

25.3. RUBBING OF SOAP

SOLUTION:

This stage is especially incorporated to

get more effective cleaning. In this

stage, soap solution is rubbed and

made even application on both sides of

coach by two vertical nylon brushes

one at each side of coach .This stage

comes into action as soon as sensor at

second stage is activated.



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bbooaarrdd,, ttuurrnn uunnddeerr aanndd rrooooff ppoorrttiioonn..

EEaarrlliieerr,, tthheessee aarreeaa ccoouulldd nnoott bbee

ppoossssiibbllee ttoo cclleeaann bbyy oolldd ccooaacchh

wwaasshhiinngg ppllaanntt.. TThheessee bbrruusshheess aarree aallssoo

hheellppiinngg iinn rreemmoovviinngg ooff rreesseerrvvaattiioonn

cchhaarrtt ppaasstteedd oonn aa ccooaacchh..

25.6.COACH CLEANING BY HORIZONTAL AND VERTICAL BRUSHES:

WWhheenn ccooaacchh iiss mmoovviinngg tthhrroouugghh tthhiiss ssttaaggee,, ffiirrsstt rruubbbbiinngg ooff ssooaapp ssoolluuttiioonn ttaakkeess

ppllaaccee aatt rrooooff ppoorrttiioonn bbyy hhoorriizzoonnttaall nnyylloonn bbrruusshh mmoouunntteedd oonn ttoopp ooff tthhee IIVVtthh

ssttrruuccttuurree..



25.8.MOPPING OF WATER: After wash, coach body become

completely wet hence it require mopping. Two vertical brushes with

soft cotton threads are provided each on either side. These brushes

start mopping of water particles on sides of coaches as soon as coaches

pass through these brushes.

This stage is specially effective for

cleaning of AC glass windows where

small water drops are always sticking

and staining glass giving discomfort to

passengers when they are looking

outside through such windows. These

brushes are also used for buffing of

coaches to get shining by rotating it in

dried condition when rake is moved

from pit-line after examination. Since,

requirement of soap solution is less for

external cleaning of rake by this washing

plant. Cost incurred in normal external

cleaning of a rake of 21 coaches is Rs.

400 approximately. This cost includes

cost of material like soap solution and

cotton ropes (which are normally

replaced once in a month) and cost of

electrical power.

25.7. AFTER WASH: In this

stage, washing of roof and sides

of coaches are carried out after

rubbing of soap solution by

vertical and horizontal brushes.

High-pressure water is sprayed on

coach surface through eight high-

pressure sprinklers to wash coach

completely. In this stage, washing

of roof takes place just before

washing of sides by spraying of

water through high velocity

sprinklers provided at top of

structure. This arrangement is

made purposely to allow dirty

water after roof washing to flow

down on both sides of coaches

before washing of sides of

coaches.



26.0 INTERNAL COACH CLEANING MACHINE

This machine is departmentally designed and developed for cleaning of

coaches internally. It is operated on 220V AC as well as 110VDC supply

thereby any coach lying any where in the yard can be cleaned by this

machine as 110V DC supply available in a coach. Construction of this

machine is sturdy and light in weight about 6 Kg hence it is easy to handle.

Due to light weight and 1.2 meter length of machine, staff can do effective

cleaning work in standing position without fatigue. At present, this machine

is specially used for toilet cleaning and intensive cleaning of floor, berth,

side wall by using various type of brushes.

FLOOR CLEANING BERTH CLEANING

WINDOW GLASS CLEANING TOILET CLEANING



27. 0 Justification of ACWP proposed for Coaching Depot

Automatic Coach Wash Plant : Cost Rs. 4.0 Crores Assuming no. of rakes examined per day in a depot = 6 rakes Average no. of coaches per rake = 21 Total no. of coaches examined per day = 126 Man power required for outside cleaning = 0.6 man/coach Saving in manpower for 108 coaches ( per day) = 126*0.6 = 76 men days Considering average wages of Rs.12000/- month or Rs.400/- day Monetary savings per year = 76x365x400 = 1.11 Crore The ROR is expected to be about 15 % Intangible benefits 1. Saving of water with ACWP (with 60% recycling) =6000 litres/rake Saving of water per day for 6 rakes = 6000x6 = 36000 litres = 36 kl Water is a scarce commodity in several areas and conservation of water is imperative

to save this invaluable natural resource.

2. Since the work of external train washing will no longer be carried out at pit line,

drainage problems will be less and the working conditions will improve, leading to better

productivity.



28. Justification of Coach Lifting Plant proposed for Coaching Depot Cost : Rs.3.0/- Crores

Justification: At present ineffective % of coaching stock in sickline is 2.5 to 3 %. Underfloor

carbody lifting plant is proposed for lifting of coach body for maintenance in the sick line for

reduction in lifting time and safety in operation. By providing UCLP the lifting time of coaches

will be reduced considerably. On an average 4 – 6 coaches are lifted in a major coach depot.

Assuming 2 hrs. saving in lifting and lowering of coach the average saving is about 2 x 5 coach

hrs.

Annual Saving = 2 x 5 x 360 = 150 coaches in a year

----------------

24

Annual saving in Rs. =150 x 30000 = 45 lacs per annum

Further there will be saving of manpower and also ensure safety at work.

29.0 Covered shed

Well lighted all weather covered shed for examination and maintenance of subassemblies as per

Railway Board‟s letter no.97/M(C)/137/1 Vol.VI dt.09.06.04. The proposed pre engineered

building covered shed is cheaper than conventional one (Conventional shed Rs.25 Cr. v/s PEB

shed Rs.20 Cr.) The pre-engineered buildings covered sheds have following features:-

Simple design and light foundations

Standard component connections

Fast and standardized erection process

Low weight flexible frames offer higher resistance to seismic forces

Future expansion is simple and cost effective

Lighter structure weight

Aluminum sheet offers high corrosion resistance



30.0 Justification for all weather shed for Coaching Depots

Covered all weather shed has been proposed for coaching depots. Detailed justification is as

follows –

1. Earlier the examination was carried out every 1500 Kms. Now with the latest

instructions for coaching train examination, round trip examination is carried out every

3500 Kms. Any laxity in examination is detrimental to the quality, reliability & safety in

operation.

2. Examination has to be carried out in limited time schedule of 6 hours, which involves

external washing, internal cleaning, under gear examination, brake gear checking, wheel

defects examination, change of springs, brake blocks and other defective fittings.

Examination in the open sky is particularly arduous in rainy season and in extreme hot

and cold weather conditions.

3. In case of working in adverse weather like heavy rains, not only the productivity of staff

is affected, it also leads to detaining of rake for longer period of 8 to 10 hours (as

compared to 6 hours scheduled time given for attention).

Financial Justification –

No. of rakes attended per day : 6 nos.

(at 2 pit lines)

No. of coaches attended per day : 126 nos.

(av. 21 coaches per rake)

Loss of time while working in Extreme

weather condition (@ 3 hours per rake) : 126 x 2 = 252 hours per day

No. of days with extreme weather condition : 180 days.

In a year

Total loss of coach hours : 252 x 180 = 45360 hours.

Total loss in coach days :45360/24= 1890 coach days.

Loss in term of earning potential of coaches : 1890 x Rs. 30,000

= Rs.5.67 Crores.

Cost of covered shed : Rs. 20 Crores

Break – even point : Less than 4 years.

The ROR is expected to be about 15 %



Apart from above, there is loss of punctuality due to delayed availability of the rake, which

affects the operation of other trains also. The loss due to poor reliability leading to enroute

breakdowns can be minimized by the use of covered sheds. With the improvement in working

conditions, the quality of safety checks and overall safety shall be improved. Better working

conditions are bound to improve staff morale and are likely to reduce absenteeism due to

sickness resulting from working in adverse weather conditions. Therefore, covered shed is

desirable from techno – commercial considerations.

Better outturn with proposed facilities

With one hour saving in examination time in pitline due to attention of rakes in better working

condition

Savings expected in time required for attention = 1.5 hour

( due to better working condition)

Saving of coach hours (for 108 coaches examined / day) = 178 coach hrs.

As per traffic account figures the earnings per coach per day = Rs.30000/-

Monetary savings (in terms of earning capacity) = 178/24 x 30000 x 365

= 8.1 Crores

This is in addition to manpower savings due to introduction of various M&Ps like Automatic

Train Wash Plant and Wheel Diagnostic System.

Overall Justification: Cost of project : 60.55 Crores Savings due to saving in examination time on pit line = 8.1 Crores

Savings due to covered shed = 5.67 Crores

Savings with ACWP = 1.1 Crores

Savings due to Coach lifting system = 0.45 Crores

Total savings = 15.32 Crores per year

Break – even point : Less than 4 years.

The ROR is expected to be about 15 %



31.0 PROPOSED LIGHTING SOLUTION OF COACHING DEPOT

1.0 RECOMMENDATIONS

The illumination level for all working areas i.e. above catwalk, below catwalk

and underpit should be 100-150 lux for smooth and efficient working.

For overhead lighting under covered shed for the purpose of general shed area

and above catwalk lighting, metal halide lamp fittings blended with energy efficient T5

fluorescent lamp fittings with Inverter backup are recommended.

Metal halide lamps are recommended in place of mercury/ sodium vapour lamps

due to its best colour rendering properties. Metal halide excels in meeting the complex

demand of energy efficiency, light quality, light output and lamp life.

The basic problem with metal halide lamp is its high re-striking time (approx. 4

to 6 minutes), to avoid the total blackout during the above re-striking period after

restoring the power supply, the over head lighting is blended with energy efficient T-5

fluorescent lamps at each alternate position.

Multiple T-5 fluorescent lamps with electronic ballast have following beneficial

features:

Energy efficient (lumens/ watt is 90 to 100)

Instant start- no flickering & continuous illumination.

High colour rendering index i.e. true colours

Uniform distribution of illumination i.e. no shadow area at work place.

High power factor i.e. more than 0.95.

For illumination below catwalk and under-pit, Power LED based luminaires are

recommended. LED based energy saving lighting have following beneficial features:

More power to light instead of power to heat.

Energy efficient (Lumens per watt 90 to 110 lumens).

Pure white light, high colour rendering index i.e. true colours.

Long life span, more than 10 years. Eliminates maintenance cost on bulb

or CFL replacements.

For directed maintenance, staff may use helmet based LED lights for precision work.



1.1. OVERHEAD LIGHTING FOR COVERED SHED

Lighting for general shed area.

Illumination required : 100 – 150 lux

Mounting : Overhead fixed on covered shed structure

A-

B- BLENDING OF LIGHTS

Metal Halide + blending with alternate fitting of T-5 tube light in each row (For quick

recovery of lights after power failure).

SPECIFICATION FOR 250W METAL HALIDE LIGHT FITTING:

Specification for light fitting luminaire shall be as given below:

Voltage : 230V AC 1, 50Hz

Lamp : 250 watts Metal Halide Lamp

Lamp type : Single ended clear elliptical Metal Halide lamp

Lamp base : E – 40.

Lumen output : 20000 – 22000 lumens

Luminaire : Integral side mounted totally enclosed mid bay luminaire.

Lamp holder base : GES(E40), skirted porcelain.

Reflector

: Electrochemically brightened, high purity stainless steel

parabolic reflector with glass assembly.

Glass assembly : Glass and gasket assembly with toggles which shall be swung

open for easy maintenance and shall be secured with chain

arrangement.

Control gear

: Heavy duty copper wound ballast, ignitor, and power factor

correction capacitor suitable for 250 watt metal halide lamp.

The control gear cover shall be swung open 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 : 18 mm ID Eye bolt with adjustable mounting plate for well

aligned suspension.

Wiring : All accessories of luminaire shall be prewired up to terminal

block.



Tightness level : For lamp compartment IP 54.

For control gear compartment IP 43.

IS : Luminaire shall confirm IS: 10322.

Make : Philips, Crompton Greaves, Bajaj, Osram, Wipro, GE, Asian.

SPECIFICATION FOR T-5 FLUORESCENT LIGHT FITTING:

Voltage : 230V AC 1, 50Hz

Lamp : 4 x 24 watt, T-5 energy efficient fluorescent Lamps

Energy efficient high bay fitting made of extruded

Aluminium body, consisting with 4 Nos. separate Electronic

ballast operative in 130V-300V, THD less than 10%, having

power factor more than 0.95, suitable for 4 x 24W T-5 lamps

system complete with lamps. The fittings shall be provided

with suitable hanging arrangement. Luminaire shall be

provided with acrylic dust cover.

Model : JBFKS 43300 of Asian or similar.

Make : Philips, Crompton Greaves, Bajaj, Osram, GE, Wipro, Asian.

Approx. Dimensions : 600mm x 600mm x 65mm

LIGHT FITTING CONFIGURATION

Overhead light fittings should be located at the roof structure of the shed just

above the catwalk.

Distance between the two fittings in a row along the shed length shall be 8.0

metres.

Light fittings configuration between two rows shall be planned in zigzag manner.

SUPPLY AND CONTROL ARRANGEMENT

Overhead 3-phase, 4-wire system laid with suitable brackets and insulators along

the shed structure under the roof.



1.2 BELOW CATWALK LIGHTING

For lighting below catwalk area.

Required illumination : 100 – 150 lux

SPECIFICATION FOR LED LUMINAIRE

Specification for LED luminaire shall be as given below:

Input voltage : 48 V AC +/- 10%

Input power : 22 Watts

Power factor : > 0.90

LED matrix : 15 LEDs matrix

Approximate light output : 1600 – 1700 lumens.

LED Driver : High brightness driver system

Source : PWM constant current

Reverse polarity protection : Yes

Short circuit protection : Yes

Open circuit protection : Yes

Material and insulation of driver : Fire retardant material (ABS & Polycarbonate)

Diffuser : P12 prismatic polycarbonate & toughened glass

Tj (Junction temperature) : Less than 90° C of each LED after continuous

operation of 12 hrs.

Luminaire type : IR-GOLD-B1 of M/s Goldwyn Limited, 15 & 16, Noida SEZ

Noida – 201305 OR SIMILAR

Dimensions : The approximate dimensions of luminaire shall be as shown below:

The whole luminaire fixture shall be provided with high impact resistance i.e. IK10.

The whole luminaire fixture shall ensure tightness level of IP 67.

210.00

150.00

190.00 ARRANGEMENTALLEN SCREW

170

270

320

72



All accessories of luminaire shall be pre-wired upto the terminal block and the connecting

lead wire shall be 3 core (phase, neutral & earth), PVC insulated of suitable size and

minimum 1.0 m long.

Mounting arrangement : Luminaire shall be provided with suitable mounting

arrangement.

Luminaire shall be suitable for semi flush/fully flush/ surface

mounting.

Locking arrangement : The top cover of the luminaire shall be fitted with allen screws to

avoid theft.

Light fitting configuration

One fitting on each catwalk pillar.

Supply and control arrangement

48 V AC lines shall be fed from six points by suitable transformers for individual

catwalk.

Single core copper cable of suitable size PVC insulated 650/1100V confirming to IS :

1554/694 Pt. I-1988 shall run through GI pipe under the catwalk pathway and pillars.

Cable shall be provided with junction box of suitable size on each pillar for

connection of light fitting. Each row of light fitting shall be provided with suitable

ratings MCCBs.

Load of light fittings shall be equally distributed on all three phases of supply.

Metal body of each light fitting should be connected to the earth properly.



1.3 UNDER PIT LIGHTING

For lighting under-pit.

Required illumination : 100 – 150 lux

SPECIFICATION FOR LED LUMINAIRE

Specification for LED luminaire shall be as given below:

Input voltage : 48 V AC +/- 10%

Input power : 16 Watts

Power factor : > 0.90

LED matrix : 12 LEDs matrix

Approximate light output : 1300 – 1400 lumens.

LED Driver : High brightness driver system

Source : PWM constant current

Reverse polarity protection : Yes

Short circuit protection : Yes

Open circuit protection : Yes

Material and insulation of driver : Fire retardant material (ABS & Polycarbonate)

Diffuser : P12 prismatic polycarbonate & toughened glass

Tj (Junction temperature) : Less than 90° C of each LED after continuous

operation of 12 hrs.

Luminaire type : IR-GOLD-C1 of M/s Goldwyn Limited, 15 & 16, Noida SEZ

Noida – 201305 OR SIMILAR

Dimensions :The approximate dimensions of luminaire may be as given below.

140

240

290

72

124

160

210

59 65

WASHER

ED COATING

PRISMATIC POLYCARBONATE DIFFUSER WITH TOUGHENED GLASS



The whole luminaire fixture shall be provided with high impact resistance i.e. IK10.

The whole luminaire fixture shall ensure tightness level of IP 67.

All accessories of luminaire shall be pre-wired upto the terminal block and the connecting

lead wire shall be 3 core(phase, neutral & earth), PVC insulated of suitable size and minimum

1.0 m long.

Mounting arrangement : Same as given in section II.

Locking arrangement : Same as given in section II

Light fitting configuration

One fitting on each alternate pillar under the rail.

Opposite pillars under the rail shall have fitting in zig-zag configuration.

Supply and control arrangement

48 V AC lines shall be fed from six points by suitable transformers for individual

pit.

Single core copper cable of suitable size PVC insulated 650/1100V confirming to

IS : 1554/ 694 Pt. I-1988 shall run through GI pipe under the pathway and rail

pillar inside the pit.

Cable shall be provided with junction box of suitable size on alternate pillar under

the rail, fitted with light fitting for connection.

Each row of light fitting shall be provided with suitable rating of MCCBs.

Load of light fittings shall be equally distributed on all three phases of supply.

Metal body of each light fitting should be connected to the earth properly.

2.0 ELECTRICAL LOAD

The approximate electrical load has been calculated considering the design of

coaching complex 620 m long, 14.39 m wide having two tracks as given below.

S.No. Description Qty. Load (in kW)

Overhead lighting

1 250W MH fittings (assuming 300W load with choke) 150nos. 45.0 kW

2. 4 x 24 W T-5 fittings (assuming 110 W load with

electronic choke)

150 nos. 16.5 kW

Below catwalk lighting

1. 22 W LED light fittings (assuming 25 W with driver) 425 nos. 10.5 kW

Under-pit lighting

1. 16 W LED light fittings (assuming 18W with driver) 750 nos. 13.5 kW

Total 85.5 kW

load in kW = 85.5 kW Load in kVA = 107 kVA (Assuming PF 0.8)



COACHING COMPLEX LIGHTING ARRANGEMENT

1. Above design of coaching complex is being prepared by Mechanical Directorate of IRCAMTECH/Gwalior.

d1250

960

a) Electrical Cables

b) Water pipe

c) Water drainage

2. All dimensions are in mm and not to scale.3. Circles show the locations of different light fittings.

d) Pit light

2000590

C

250850

250

600

G.L.

6000

4025

b

3245

a

785d

3700

250

1300

b

1800

3245

14190

Ground Level3 m

3 m

Ind. fan

5 m

Exhaust fan

a



Additional/Optional

provisions



Waste removal system for Vacuum Toilets (Mobile)

Description : Battery powered waste removal system with rotary displacement pump and

waste tank

Source of supply : Evac , Wedel, Germany

Bio-Toilet evacuation system for Bio-Toilets (Mobile)

Description : Trolley mounted garbage removal system with displacement pump and waste

tank

Source of supply : Vogalsung, Noida, U.P



Waste removal system for Vacuum Toilets (Stationary)

Description : Waste emptying system with rotary displacement pump



Waste removal system for Vacuum Toilets

(Stationary)

Emptying system - Vacuum central



33.0 Suggestions given by Zonal Railways for Pre-Fab pit line &

coaching depot infrastructure during seminar on 21.07.2014

Pit line: Dy CME/NWR, Sr DME/BSP & Dy CME/GKP stated that prefab pit line in line with

DMRC will be suitable but both side catwalks are required alongwith long span supports below

catwalk.

Catwalk: Catwalk is necessary for changing of destination boards, cleaning of exterior,

attention to doors, cleaning of roof and attention to ventilators. But these catwalks make clumsy

situation due to supporting pillars, hence it is suggested that pre-fab longer span catwalks may

be developed for better and safe maintenance.

Pre-Cast tiles: For free movement of staff from one pit line to other pit line at entry point, floor

of pre-cast tiles for atleast half of the coach length should be done for safe travelling.

Lighting arrangement: Light fittings of sufficient lux should be installed on Catwalk pillars for

under gear and trolley inspections. Single phase Welding sockets, and spare plug for hand lamps

should also be provided on this switch board.

Surface wheel lathe machine: Surface wheel lathe machine is required for coaching depots

having holding more than 250 coaches.

Maintenance bay shed: Lay out and estimation for covered shed should be done in line with

ROH depot ADI and TKD. The details may be collected from them.

Hydraulic Jacks: Hydraulics Howrah JET. And Ferro mysore are the sources for lifting

platforms.

Cleaning Machines: Sources for cleaning machines are , Karchar, Roots India, Johnson Divery

etc. Specifications may be collected from them

Revision in codal life of Linen: Some of the Railways have given suggestions that codal life of

bed sheets and blankets to be reviewed for better management of linen items.

******

draft guidelines for maintenance facilities in coaching depot on...

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