quality audit report of coaching depot tikiapara, e...

Quality Audit report

Of

Coaching Depot

Tikiapara, E Rly

Report no. 22/2012

APRIL 2012

(Audit is done by QA Mech Dte of RDSO )

of 39 Coaching depot – TKPR, E. Rly. April 2012

Quality audit Report of

TKPR Coaching Depot, Eastern Railway

1.0 Introduction

Railway Board vide letter no. 2012/M(W)814/5 dated 20.3.12 has instructed RDSO / Zonal Railways to conduct quality audit of coaching depots and workshops. QA (Mechanical) Directorate has been assigned to carry out audit of 10 coaching depots. Kolkata Zone of QA(Mech)/RDSO has been assigned to carry out audit of 03 coaching depots (TKPR/HWH/ER, NCC/SDAH/ER and SRC/KGP/SER) by Executive Director/QA(Mechanical).

1.1 Audit team - S/Shri M A Alam, Director/I&L/Kolkata, S Bose, AIE/I&L/Kolkata and Dileep Kumar, JE/I&L/Kolkata & B K Sahoo, JE/I&L/Kolkata

1.2 Date of audit - 29.03.12 & 05.04.12

1.3 Escorting officers from depot - Sri S Vijay, Sr DME(C&W)/HWH & Sri Achinto Roychoudhary, CDO/TKPR, Sri P Mishra, SCW/TKPR and concerned SSE/C&W/TKPR.

1.4 Scope of audit - Primary maintenance of coaching rakes –under gear attention (pit attention) and rolling–in examination of terminating trains, coach cleaning, fitment of passenger amenities items, schedule attention of coaches ( POH, IOH, Schedule A and Schedule B), pest control management in AC and Non-AC coaches, detachment of coaches (primary, secondary and en-route) and its analysis, maintaining records –DDR (damage deficiency register), feedback/ complaint and action taken, linen management and availability of Stores & its management. After audit, Sr.DME/C&W/HWH and his team have been briefed about observation noted during audit.

2.0 Brief about visit

TKPR coaching depot, Howrah is one of the oldest coaching depot with holding of 740 coaches and is a major coaching depot of Eastern Railway.

Total 3 deep pit lines with catwalk as per CAMTECH design and other 12 deep pit lines without catwalk are available to carry out 18 primary maintenance, 1 secondary maintenance and 7 round trip maintenance of important Mail/Express trains such as Kolkata Rajdhani, Duranto Exp (HWH-NDLS), Ranchi Shatabdi, Bagh Express, Delhi Superfast and Doon Express etc.

Depot is also maintaining one Double Decker service (HWH–DHN) consisting of 7 coaches.

During two days of audit, items as per scope of audit have been checked. Relevant records have also been checked. Infrastructure availability in the coaching depot and planning of inputs has been studied. The escorting


officers and supervisors have given all assistance to audit team and escorted the audit team during audit.

3.0 Strengths

3.1 Depot has provided LED destination board in 222 coaches of important Mail/Express trains against RSP. Coaches of Kolkata Rajdhani Express (12301/12302 &12305/12306), Duronto Express (12273/12274), HWH - DLI superfast (12323/12324) and 5 link trains of intercity express have been provided with LED destination board (including spare coaches).

3.2 Depot has installed one mechanized laundry as per RB’s guidelines. Total 3500 packets are washed daily from this mechanized laundry since last 15 months. Quality of washed linen is good. Depot has total requirement of 5000 packets per day. Balance quantity is arranged through washing contract in mechanized laundry. Close monitoring for linen quality is ensured. Complaints on account of linen have reduced to 4 cases in 2011–12 as compared to 50 cases in 2010–11.

3.3 OBHS through outsourcing as per RB’s guidelines has been provided in 14 important Mail/Express trains. In Duronto Exp (HWH – NDLS), HWH – NDLS Bi-weekly Express and other important M/E trains, OBHS through outsourcing have been provided. Depot is providing OBHS in LHB Rajdhani (HWH – NDLS) by deploying C&W staff. This has resulted in passenger satisfaction.

3.4 Depot is carrying out maintenance of CDTS, fitted in LHB coaches through in-house and all CDTS are working. Spares are procured through OEM. Depot has rigged up one CDTS test bench for testing of components before fitment in coaches.

3.5 Supervisor and staff are trained. Depot has good safety performance and there is no derailment / accident on C&W account.

3.6 Minimizing Jerk in LHB: ER has taken action to reduce jerks in LHB coaches. Draft gear pre-load has been reduced to 35 KN from 50 KN. Total 64 FTIL make and 14 Escort make CBC with draft gear have been fitted in LHB coaches. Complaints on account of Jerk reduced from 19 cases in 2010 – 11 to 02 cases in 2011 – 12.

3.7 Publication of Pocket Book on LHB & ICF type coach Maintenance &

Trouble Shooting: To ensure safety maintenance - Pocket books for both LHB & ICF type coaches, contains Operation and Maintenance as well as Trouble shooting guideline have been published by the Division as a ready reference for Officers, Supervisors and staff.


3.8 Improvement on ‘Last vehicle Indication’ ‘X’ mark on LHB type Rajdhani Power cars: In LHB Power car, last Vehicle indication i.e. yellow ‘X’ was rather small reducing its visibility specially in foggy season. The same has been improved by retro-reflective sheet for better visibility, especially during night time.

3.9 Provision of protection clamp on FTIL make brake calipers in LHB type Rajdhani coaches: To prevent dropping of brake pad from FTIL make brake calipers, depot has developed a ‘C’ type protection Clamp to prevent lateral movement of Snap lock. This will avoid en-route failure/detention of Rajdhani Express due to falling of brake pad.

‘C’ type protection

Clamp


3.10 Mesh-guard protection in air spring coaches for Duranto express: Depot

has provided mesh-guard protection over air spring and air reservoir/piping in

Hybrid Duranto coaches to avoid breakage of leveling valve & its’ assembly

and prevent deflatening of air spring suspension system on run.

Protection covers for air spring Protection covers for air reservoir.

3.11 Divisional training school for training of Artisan and other category of staff: Depot has developed good facility to carry out training of various categories of staff in safety and housekeeping of coaching stock. A well established training school with full air brake model of coaching stock has been provided in depot for training of all categories of staff.

4.0 Weaknesses

4.1 Depot is not aware regarding list of safety items published by RB and following their own list of safety items. There is crisis of some safety items (K type brake block) and passenger amenities items. Non availability of cleaning


and disinfecting chemical affects quality of cleaning. Stock of Oxalic acid for outside cleaning and pine oil for disinfection is critical. Quality of outside cleaning of trains (except Rajdhani) was found not satisfactory during audit on 28.03.12. For Rajdhani maintenance, better quality cleaning and disinfecting solution are procured through non-stock procurement.

4.2 Mechanized cleaning through contractual agency is carried out in 4 PM trains and 4 RTM trains. High pressure jet pipe lines are available for Rajdhani maintenance only.

4.3 Pest control is awarded to M/s Pest Control India. As reported by depot, Performance of existing pest control agency is not satisfactory. Close monitoring is required by depot for pest control through contractual agency. Depot has taken some additional initiative on its own for pest & rodent control management. Depot is also applying Boric acid under the berth. Due to close monitoring by depot, pest /rodent complaints during last six month (Oct’11 – Mar’12) is 6 cases as compared to 11 cases in the first six months (Apr’11 – Mar’11).

4.4 Regular feedback from coach attendant for linen quality and pest infestation are not available at depot.

4.5 Howrah Division (Engineering / Medical Department) has not taken any rodent

control measure for platform area. Existing contract already has expired. Rodent control measure is available for depot area only (carried out by C&W department).

4.6 Manpower available for under gear examination and sick-line attention is 444

staff against requirement of 489 staff. Depot has processed for sanction of additional staff.

4.7 Passenger amenities in Non AC coaches (GSCN) such as magazine bags, bottle/tumbler holders and snack tables are missing. As reported by depot, shop is not providing these items in Non AC coaches. Snack table in NAC coaches are provided directly over L.P sheet and this worked out during service.

4.8 Reports of deficiencies/ defects in Rolling Stock (DRS) reports in the proforma

given in Annexure 1.2 of CAMTECH manual are not prepared jointly. On arrival of the train at the destination station, joint report for deficiency in rolling stock has not been prepared.

4.9 D3 schedule of LHB coaches (six monthly schedule attentions) is not

adequate as coach is not detached from rake for attention in sick-line. Attention is given at pit line in rake.


4.10 With existing system, grease oozing out in LHB wheel sets can be checked from front seal only when front cover is opened. This is being checked during D2 /D3 schedule as front cover is opened for attention. For checking grease oozing out at rear grease seal, bottom control arm is to be taken out. Checking of grease oozing out in LHB wheel sets is not done for rear end seal at depot.

4.11 INFRASTRUCTURAL CONSTRAINTS OF TKPR: Depot has non-standard

maintenance infrastructure. The following major bottlenecks have been reported by depot:

Non standard Deep pits: Pits available are of non standard design without

cat-walk. Inadequate spacing between two pits: The space between two pits is

narrow on account of track centre being less. Curved Maintenance Line: All lines in yard are curved. Inadequate drainage system – Existing drainage system is not adequate

for complete drainage, especially during rainy season. The outlet through Howrah Municipality is almost blocked. Overall drainage system including lay out is required to be upgraded.

Remodelling work is in progress : To overcome the above constraints, the following remodelling of TKPR depot has been planned and works sanctioned: In PH-I: 03 deep pits of CAMTECH design with Catwalk have been

constructed. In PH-II: Sanctioned in PWP (10-11) at the cost of 45.04 crores.

Total 04 deep pits with catwalk and one stabling lines with washing apron will be constructed.

4.12 Shortcomings have been noted in area which is not directly attributed to depot

but need attention at respective level for better performance of coaching depot and reliability of rolling stock: Total 41 ICF wheel sets attended in sick-line due to grease oozing out

during 2011-12. This need attention by concerned POH shop. There are 84 cases of primary detachments of ICF coaches due to

water tank leaky in 2011–12 as compared to 69 cases in 2010–11. Depot has no facility for water tank testing. Only hydrant line is available.

There are 22 cases of primary detachments due to DV defect (ICF

coaches) in 2011–12 as compared to 13 cases in 2011–11. Total 08 cases of brake binding have been reported en-route during 2011–12. This need attention by concerned POH shop.


As reported by depot, adequate time at en-route watering station for coach watering has not been provided. Kolkata Rajdhani (HWH– NDLS) has only 10 mts stoppage time at MGS for coach watering.

For facilitating inspection of sole bars, even spaced elongated holes of

(215x127 mm) have not been provided in the turn under of all coaches. One coach in sick line has been checked and observed that coach ER 10421 (built ICF: 8/10 & POH/LLH -20.01.12) is not provided with elongated holes of 215x127 mm size.

Contract for disc brake (including air brake) attention in LHB coaches

for KB makes and FTIL brake systems have expired. Depot is carrying out maintenance attention of phonic wheel / speed sensor / brake caliper through in-house. As reported by depot, shop is not attending disc brake system during POH / IOH attention as contract with KB and FTIL expired and new contract is yet to be awarded by shop.

Wheel sets are cannibalised during maintenance and wheel sets sent

to shop when due for CTRB attention (at 3 years interval). It is observed wheel sets with life of more than 2 years are in service at depot without UST of axle. As per guidelines circulated by DG/M&C/RDSO vide letter no. M&C/NDT/1/8, ICF axle need to be given UST at one year interval. No such guidelines have been circulated for LHB wheel sets. Presently LHB axle is attended for UST when wheel sets touch the workshop. Due to absence of guidelines for LHB wheel sets, depot is not attending wheel sets for UST of axle.


Quality Assurance Directorate (Mechanical) RDSO Lucknow

Check sheet for Quality audit of coaching depot

Primary maintenance attention and sick line attention

(Based on CAMTECH Maintenance Manual for BG coaches

and Railway Board / RDSO’s guidelines)

Location: TKPR Coaching Depot, Howrah

Date of audit: 28.03.2012 & 05.04.12

S.N 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 as per Railway Board’s guidelines is followed. ICF & LHB coaches are given POH attention at LLH shop. Status of POH attention during 2011 - 12 is as under:

AC 158

NAC 826

Total 984

Overdue POH as on 01.04.12 is 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 an Correction slip 5 for coaching maintenance manual issued in 2008 RB letter no. 2007/M ( C)/141/1 dtd 26.09.08

TKP Depot/HWH has a bare holding of 613 coaches and total holding of 740 coaches (including maintenance spare and traffic spare). ICF coaches – 604, LHB – 75, Duronto (Hybrid) - 28, Double Decker – 17 & Satabdi (Conv) – 16. Schedule A & B attentions in rake are being carried out as per recommended frequency for ICF coaches. LHB coaches are also attended as per recommended frequency. (D2 schedule at one month interval and D3 at six month interval). During last 6 months,

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

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

5 IOH attention - detach coaches Periodicity of IOH attention:


S.N Item Clause Observation 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

Total A schedule carried out : 2072 Total B schedule carried out: 849 Overdue A and B schedule: NIL Existing sick line at TKPR depot has 5T crane facilities. 25T carne is under installation. IOH attention is given at LLH shop as well as depot. Lifting at depot is being done by JMP Jacks. Total 16 nos. jacks are available at sick-line. Shop is supplying overhauled bogies. BRN wagons have been converted with provision of screw coupling. Bogies are supplied to depot in BRN wagon and arrived/dispatched with POH load. Newly built coaches (ICF design) are attended at SYAE Depot/HWH as per Board’s guidelines. During 2011, status of IOH attention for ICF design coach is as under:

IOH attention at LLH shop 347

IOH attention at Depot 104

IOH attention of newly built coaches

-

Total IOH attention of coaches at depot

451

Overdue IOH coaches: NIL Sick line has capacity of 16 coaches under cover shed /overhead crane facility. Pit facility is available for …… coaches.

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

112(b) of Chg.Manual This is being followed. The depot is carrying out the following attention at depot:

Mail Express trains

PM with RTM at other end 13

PM with SM at other end 5

RT attention (other base) 5

RT attention (own base) 2

SM attention of other base 1

Total attention 26

Total 47 coaches are missing over Foreign Railways. These coaches returned to base depot when due for POH.

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

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

This is being followed. All trains are examined by C&W staff before despatch.



8 Terminating Examination of Passenger Trains – Rolling in examination.

107 b of Chg. Manual

Rolling–in examination is being carried out at HWH. Deployment of staff have been checked during audit and found only 2 men deployed for rolling-in examination.

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

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

Site has un-obstructed view of under gear from both side.

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

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

Lighting arrangement for rolling–in examination is available. Light arrangements have been provided at both side of PF-1 to PF -14. These arrangements cover all in-coming Mail/Express trains.

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 Records of rolling – in examination have been checked. Temperatures of all axle boxes of Rjadhani/Duronto/Satabdi have been recorded in register. Temperature of axle boxes of ICF coaches if above 50

0C has been recorded. Depot has

been intimated by PH TXR for any defects noted during rolling-in examination. However, during audit check on 14.04.12, rolling-in staffs were found standing at site but not carrying out rolling-in examination of Shipra Express during arrival at PF.

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 Axle box temperature is measured with non contact type temperature measuring device. 06 nos non-contact infrared temperature measuring devices are available at PF.

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

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

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

This is being ensured.

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- ICF Coaches have been provided with BMBC. Piston stroke is adjusted to 32 mm during primary maintenance.

ii) Brake blocks should be changed in bogie sets only

-do- This is being ensured.

iii) All missing passenger amenity -do- All AC coaches are provided with


S.N Item Clause Observation fittings must be replaced and the rake must be turned out as ‘Zero-Missing-Fitting’ rake.

passenger amenities items. However, passenger amenities in Non AC coaches such as magazine bags, bottle/tumbler holders and snack tables are missing. As reported by depot all passenger amenities items are not provided in Non AC coaches during POH. Snack table in NAC coaches are provided directly over L.P sheet and this worked out during service.

iv) Intensive cleaning of coach toilets and lavatory.

-do- This is being ensured.

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

-do- Clear maintenance time of 6 hrs on the pit is available as per train schedule.

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

-do- TKPR depot has the following pits and stabling line for rake maintenance:

24 coach pit with catwalk and washing apron

03

24 coach pit facility without catwalk

04

Less than 24 coach pit facility

08

Stabling line with 24 coach facility

NIL

Stabling line with less than 24 coach facility

3

TKPR pits are non standard without catwalk and washing apron. Only 3 pits have been constructed as per CAMTECH design. Works have sanctioned for construction of 4 deep pits of CAMTECH design and one WA cum stabling line. 10 nos. RTR is available for air brake testing. High pressure line is available for Rajdhani maintenance pit line only (pit line 36 & 37). Facility for High pressure jet is not available for coach washing and toilet cleaning in other pits.

vii) Adequate gang strength with proper supervision

-do- The staffs available for cleaning activity are 290 against requirement of 304. Shortfall has been compensated through outsourcing of cleaning activity. Total 65 staff deployed for cleaning activity through outsourcing.



Manpower available for under gear examination is 335 staff against requirement of 354 staff. Manpower available for sick line attention is 109 staff against requirement of 135 staff.

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- This is being ensured at other end.

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

-do- This is being ensured at other end.

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- Joint certificates have not been issued for newly introduced train by Sr.DME/C&W and Sr.DOM. Total 06 new trains have been introduced, however, joint certificate covering each clause of mandatory conditions have not been issued.

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

Rake maintenance link has provision of 6 hrs maintenance time for pit attention 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

Attention is given for rake cleaning, amenities attention and watering at pit line.

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 Depot is using solution for cleaning as approved by CME. Cleaning solution is provided by contractual agency for the coaches undertaken for cleaning activity (43 coaches of PM and 65 coaches of RTM) as per contracts provision. Against MC of 3200, average consumption is only 1452. There is crisis of cleaning and disinfecting items such as Oxalic acid, Pine oil etc. this is affecting cleaning quality of rake maintenance.

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 movement/disturbance in the

109 (b)(i) of Chg.Manual Wooden wedges are applied to avoid rolling down of rake and red protection board is applied.


S.N Item Clause Observation 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 Coaches of 13009 up and 12301 up have been checked during audit on 29.03.12. External cleaning is found satisfactory in 12301 Up. However, outside cleaning is not satisfactory.

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

109 (c) of Chg.Manual Coaches of 13009 up and 12301 up have been checked during audit on 29.03.12. Cleaning of toilet is found satisfactory.

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 Coaches of 13009 up and 12301 up have been checked during audit on 29.03.12. Internal cleaning of AC coaches in 12301 is found satisfactory. However, internal cleaning of 13009 needs more improvement.

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

109(e) of Chg.Manual Coaches of 13009 up have been checked during audit on 29.03.12. Internal cleaning of GS and SLR is satisfactory.

12.7 Cleaning of buffers and screw couplings

109(f) of Chg.Manual

(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 This is being ensured.

(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 This is being ensured.

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 TKPR depot has 3 (three) deep pits with 24 coach facility. Only one train (12323 Up) is 24 coach length trains.

(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 Cleaning is being done with normal hydrant line and high pressure jet line is available for Rajdhani attention only.

(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 For en-route watering, adequate time at en-route watering station has not been provided for Kolkata Rajdhani (12301/12302 & 12305/12306) has



stoppage time of 10 mts at MGS for coach watering.

(iv) Availability of the prescribed air brake maintenance and testing equipment.

110(a)(iv) of Chg.Manual Total 10 nos. RTR are available for air brake testing. Air pressure is 10 – 7.5 Kg/cm

2.

Compressor of 500 CFM (3 nos) and 360 CFM (1 no.) are available at depot.

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 This is being ensured

(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 All ICF coaches have been provided with enhanced capacity draw gear and screw coupling (75 T capacities). LHB /Duronto coaches are provided with H type CBC.

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 Integrity of rake is maintained.

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

110(c)(ii) of Chg.Manual This is being ensured

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

110(c)(iii) of Chg.Manual This is being ensured

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 This is being ensured. RPC 4 has been revised and PM with round trip is permitted up to 3500 Km for 24 coaches’ trains also.

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

110(c)(v) of Chg.Manual This is being ensured. Air brake testing is being done with RTR.

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

110(c)(vi) of Chg.Manual Air flow measuring valve has been provided in locomotives vii) Provision of audio visual alarm

system on the locomotive 110(c)(vii) of Chg.Manual

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

111(f)(i) of Chg.Manual Quarterly and yearly attention as stipulated is provided through outsourcing.



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

DCP type FE’s are provided as under: AC / SLR – 2 nos each Pantry car – 04 nos. Generator car – 02 nos.

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 C&W department is providing FE’s and wooden wedges in trains. Other equipments are provided by TL, S&T and traffic staff. All items of brake van have been kept in SLR and Almirah is sealed.

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 ASN & MLDT are nominated CTS in ER. Watering station is ASN, MLDT and RPH in ER

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 This is not being followed. DRS reports are not prepared jointly.

(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 This is not 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 Coaching depot is maintaining coach maintenance history in computer (in Access based software) which is accessible to coaching depot officer and supervisors. However coaching workshop is not linked with depot for assessing coach history. During POH, depot is furnishing coach



history details to shop in hard copy.

(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 This is not being followed.

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 This is being followed. The depot is carrying out the following attention at depot:

Mail Express trains






Total attention 26

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

113(b) of Chg.Manual This is being followed.

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.

113(c) of Chg.Manual This is being followed.

19.4 In addition to above the following items of work should be attended during the maintenance schedule examination: * underframes * 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.

113 (d) of Chg.Manual This is being followed. However, under gear cleaning is not satisfactory to facilitate examination of under-frame, bogie frame, axle box and springs etc.

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

113 (e) of Chg.Manual This is being followed.

i) Oil in hydraulic dash pots of Rajdhani and Shatabdi coaches

113 (e) (i) of Chg.Manual

Oil level in dash pot is checked on monthly basis and oil is filled up on


S.N Item Clause Observation 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.

need basis.

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

113(e)(ii) of Chg.Manual This is being followed.

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 This is being followed. ICF coaches have been provided with BMBC and piston stroke is adjusted to 32 mm by depot during PM.

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.

113(f)(i) of Chg.Manual This is being followed.

ii) Door latches and safety catches 113(f)(ii) of Chg.Manual This is being followed.

iii) Door lock handles 113(f)(iii) of Chg.Manual This is being followed.

iv) Tower bolts 113(f)(iv) of Chg.Manual This is being followed.

v) Window shutters should neither be tight nor loose

113(f)(v) of Chg.Manual This is being followed.

vi) Window shutter safety catches 113(f)(vi) of Chg.Manual This is being followed.

vii) Window frame 113(f)(vii) of Chg.Manual This is being followed.

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

113(f)(viii) of Chg.Manual This is being followed.

ix) Water pipe connections, flushing valves, cocks and shower roses should not be leaking or choked.

113(f)(x) of Chg.Manual This is being followed.

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 This is being followed.

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

113(f)(xii) of Chg.Manual This is being followed.

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

113(h) of Chg.Manual Depot is maintaining record of PM in DDR. Records for Upper body and under gear are maintained in one register. All relevant records are maintained for rake wise during PM


S.N Item Clause Observation attended at specific periodicity. Record to be maintained in standard DDR (Damage deficiency register)

of rake.

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 This is being followed.

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

114(b) of Chg.Manual This is being followed.

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

114(c) of Chg.Manual This is being followed. Record of schedule ‘A’ examination is maintained in printed schedule form.

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 This is being followed.

ii. The specified items of work should be attended.

115(b) of This is being followed. Record of schedule ‘B’ examination is maintained in printed schedule form.

iii. Brake system maintenance

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

Chg.Manual This is being followed.

iv. Other assembly maintenance

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

115(b)(i) of Chg.Manual

This is being followed.

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

b. Painting of lavatories from inside. 115(b)(iii) of Chg.Manual This is not being followed. Attention is given on need basis.

c. Thorough inspection and repairs of brake gear components.

115(b)(iv) of Chg.Manual This is being followed.

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

115(b)(v) of Chg.Manual This is not being followed.

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

115(b)(vi) of Chg.Manual This is not being followed. Attention is given on need basis.

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

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

Existing sick line at TKPR depot has 5T crane facilities. 25T carne is under installation. IOH attention is


S.N Item Clause Observation 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

given at LLH shop as well as depot. Lifting at depot is being done by JMP Jacks. Total 16 nos. jacks are available at sick-line. Shop is supplying overhauled bogies. BRN wagons have been converted with provision of screw coupling. Bogies are supplied to depot in BRN wagon and arrived/dispatched with POH load. Newly built coaches (ICF design) are attended at SYAE Depot/HWH as per Board’s guidelines. During 2011, status of IOH attention for ICF design coach is as under:

IOH attention at LLH shop 347

IOH attention at Depot 104

IOH attention of newly built coaches

-

Total IOH attention of coaches at depot

451

Overdue IOH coaches: NIL For newly built coaches, RB’s guidelines are 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

For IOH attention, coaches are detached from rake.

22.3 Brake system: ‘C’ schedule

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

117(a)(i) of Chg.Manual This is being followed. IOH coaches after attention at shop for bogies are attended at depot for IOH attention of upper body and air brake items.

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

117(a)(vii) of Chg.Manual Attended at depot for off IOH coaches as well as for coaches taken for IOH attention at depot. At shop, only bogies are overhauled and attention to air brake system and upper body is given at depot. However, intensive cleaning of off IOH coaches are not being carried out.

22.5 Other assemblies maintenance

All items of Schedule `B' 117(a)(i) of Chg.Manual Attended at depot during IOH

attention of coaches at depot.

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 This is being followed. Bogies are overhauled during IOH attention at shop. In addition, shop is supplying bogies to depot for IOH attention.



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

117(a)(iii) of Chg.Manual Attended at depot during IOH attention of coaches at depot.

22.8 Polishing of the polished surfaces.

117(a)(iv) of Chg.Manual This is not being followed.

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 Attended at shop during overhauling of bogie.

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 This is not being followed.

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

117(a)(vii) of Chg.Manual This is being followed.

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 This is being followed.

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 This is being followed.

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

117(a)(x) of Chg.Manual This is not being followed.

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 under.

117 (d) of Chg.Manual For facilitating inspection of sole bars even spaced elongated holes of (215x127 mm) are not provided in the turn under of all coaches. One coach in sick line checked and found that coach ER 10421 (built ICF: 08/10 & POH/LLH- 20.01.12) is not provided with elongated holes of 215x127 mm size.

22.16 Special attention should be taken for the following:-

117(e) of Chg.Manual

i) Pocket between sole bars and turn under 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 This is not being followed.

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

117(e)(ii) of Chg.Manual This is being followed.


S.N Item Clause Observation should be very carefully inspected for possible corrosion.

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 Records of Schedule A, B attention are maintained in standard format. For IOH attention at depot, record is maintained in standard format for upper body and under gear attention. For IOH attention at shop, record for balance items of upper-body and air brake is maintained.

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 LHB coaches have been provided in Rajdhani Expres. Hybrid coaches have been provided in Duronto Express (HWH – NDLS). ICF coaches have been provided in Satabdi Express.

22.18 The IOH of Rajdhani/Shatabdi high speed coaches should be carried out in workshops

118(c) of Chg.Manual IOH attentions of Rajdhani are carried out in LLH shop.

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.

C&W department/HWH is carrying out complete activity of linen management. However, distribution is being done by electrical department & Commercial Department.

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

Stock verification is carried out on a quarterly basis.

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.

Minimum 5 % of new linen checked by SSE/C&W as per guidelines.

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

This being ensured. Penalties as applicable are deducted from bill and payment is made after recovery of all penalties / dues.

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

Stock of 2 days washed linen is available in depot.

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

Linen items are condemned as per recommended life of linen or on condition basis.

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

A committee consisting of AME & AMM has been nominated for linen



condemnation.

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

Blankets are dry cleaned at one month interval.

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

Passenger complaints are analysed and corrective and preventive action is taken.

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

Feedback system for quality of linen from coach attendant is not adequate. CA is not reporting for linen quality in every trip.

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 control is awarded to M/s PCI. However, performance of pest control agency to carry out pest control is not satisfactory. Depot has taken some additional initiative on its own for pest & rodent control management and passenger complaint on account pest / rodent reduced to 6 complaints from Oct’11 to Mar’12 against 11 complaints from Apr’11 to Sep’11.

ii. All reserved (both AC and Non-AC) covered under contract, unreserved coaches may also be covered as per requirement of Railways

All reserved coaches (both AC and Non AC) are covered for pest control.

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.

The following frequency is adopted for pest control treatment: AC coach – Weekly Non AC coach – Fortnightly. Pantry car (AC) – Weekly. Pantry Car (NAC) – Weekly

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

Pest control management: Through fogging / only spaying

of chemicals or combination of both. 02 nos fogging machines are available. Spraying is followed by fogging of chemicals in each coach.

Chemicals used for pest control treatment of coaches: RoachEX (Propoxure), Deltamethrine, Deltamethrin Allethrin, Pest Seal (Lamda Cyhalothrin)

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

Depot has taken step for rodent control measure. Garbage from pantry cars are disposed before arrival of trains in Yard. Dry sweeping of Rajdhani coaches are done to


S.N Item Clause Observation days, on account of operational exigencies, disturbance of rake links, etc.

dispose of accumulated refuses from coaches. Refuses from OBHS operated trains are also disposed at platform. This has minimised accumulation of garbage at depot during PM of rakes. In addition, all pantry cars are unloaded at platform or in Yard for effective cleaning. Regular rodent control measure is taken inside the depot. Rodent control measure has been adopted en-route also by providing glue board in the coaches under the berths (protection net provided along partition wall for keeping glue board). However, the following shortcomings noted for rodent control: After dry sweeping of coaches,

refuses are not collected and thrown on the pit lines.

Rodent control measure has not been taken by Howrah Division (Engineering/Medical) at platform area.

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

Personnel for pest & rodent control 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

Pest control is being done in coaches detached for IOH/POH attention. Pest/rodent control is carried out in off IOH/POH coaches before inducting the coach in service.

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

All reserved coaches (AC and NAC) of a rake are given pest control treatment together.

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


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

Pantry cars are detached from rake once in a month to facilitate complete vacation and intensive cleaning for thorough pest / rodent control treatment

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

As per RB’s guidelines, pest infestation is measured by providing bait (CMT). Record of pest and rodent infestation is maintained.

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

This is being ensured. Passenger complaints are analysed for corrective and preventive action. Officer/ supervisors are deployed to collect feedback of pest / rodent



infestation in coaches.

25. Passenger amenities provided in

various types of coaches as

specified.

Board’s letter No.2006/M(C)/141/26 dt.21.12.2006.

Shop is not providing all amenities in NAC coaches such as snack table, bottle holder and magazine bag. These are found missing in sleeper coaches (NAC).

26. Infrastructure facilities –

Standard integrated modular pit line have unified maintenance.

Appendix ‘E’ of Coaching manual CAMTECH report No.CAMTECH/M/99/Infra-washing line/1.1

TKPR depot has non standard deep pits. Only 3 deep pits of CAMTECH design have been constructed. 4 more pits will be constructed. However, work is yet to be started.

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

Total 108 wheel sets attended in 2011 -12 due to canted (37 cases), grease oozing (17 cases), Grazing with wheel (16 cases), warm and hot (nil cases) and other (cover, axle box wing) etc – 38 cases.

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


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)


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:

Supervisors are aware of various wheel defects. However, CMI –K003 guidelines have not been displayed on shop floor and sick line.

a) Shattered Rim This is being ensured.

b) Spread Rim This is being ensured.

c) Shelled Tread This is being ensured.

d) Thermal Cracks This is being ensured.

e) Heat checks This is being ensured.

iv) The defective wheel should be sent to workshop for repairs after



S.N Item Clause Observation entering in the maintenance card details of the work order and date of dispatch to workshop.

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


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.

This is being ensured. En-route detachment of coaches due to roller bearing failure during last 03 years is as under:

Yr LHB ICF TOT

09 – 10

1 1 2

10 – 11

1 1 2

11 – 12

1 0 1

Each case of roller bearing failure is investigated for corrective and preventive action

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 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

This is being ensured. This is being ensured. This is being ensured. This is being ensured. This is being ensured.

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.

This is being ensured. Total 41 wheel sets have been changed in 2011 -12 on account of grease oozing out.

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

Axle box temperature is measured by non contact type temperature measuring instrument during rolling in examination. 6 nos non contact type temperature measuring instrument



are available at Howrah PF.

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


ii) If temperature is found above 800

C, the affected coach will be detached.


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

This is being ensured. Shop last issue size in off POH coaches is 837 mm

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.

This is being ensured. Wheel condemning limit in open line is 825 mm.

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 hanger should be procured as per revised spec C – 9808 Rev 2 and drg no. SK – 93286 Alt 5


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

This is being ensured. There is no hanger breakage case in 2011 – 12.

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

Shop is changing air brake hose pipe in every POH. Open line has no MC for new hose pipe. Serviceable hose pipe from shop supplied to division.

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

RDSO spec and STR This is being ensured.

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

Snack table, magazine holders on partition wall and bottle /tumbler holders are not provided in all sleeper coaches.

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

This is being ensured for HWH - NDLS Duronto Express (with Hybrid coaches).



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.


This is being ensured. Super checking report of officer is not available.

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.


Short distance Duronto with AC/Non AC chair car is not maintained at depot.

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


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.

Hybrid coaches and Double Decker coaches are fitted with air spring. Attention as recommended is given.

29.7 Analysis of sick marking and en-route coach detachment

i) Whether primary coach detachment is analysed and corrective & preventive action taken. Details of primary detachment for last 3 years to be collected.

Primary detachment from coaches are being analysed by depot for taking CA & PA. Major contribution during 2011 -12 is wheel sets due to root wear (27 %), grease oozing (4.5%),tank leaky (10.4%), Brake cylinder (4.3%), Main/Lugg/Lav door (5.9%), Bk rigging (5.3%), draw & buffing gear (5.9 %)



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

Secondary detachment from coaches are being analysed by depot for taking CA & PA. Out of 17 cases of detachment, 13 detachments reported for Rajdhani rake due to secondary spring breakge.). Summary of secondary detachment during last three years is as under:

Yr LHB/ Duront

o

ICF Total

2009 – 10

7 6 13

2010 – 11

6 3 9

2011 – 12

15 2 17

Secondary detachment is mainly on account of secondary spring breakage in LHB coaches (13 cases in 2011 – 12).

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.

En-route coach detachment is investigated and necessary corrective and preventive action is taken. Summary of en-route detachment during last three year is as under:

Yr LHB ICF Total

2009 – 10

1 4 5

2010 – 11

1 2 3

2011 – 12

1 0 1

29.8 Facilities for pit line and sick line attention

CAMTECH Maintenance

Manual for BG Coaches of

ICF design,

1st 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.

Status has been indicated in Annexure - I

30 Passenger satisfaction

30.1 OBHS & escorting of trains

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

OBHS through outsourcing as per RB’s guidelines has been provided in 14 important Mail/Express trains.

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

In LHB Rajdhani (HWH – NDLS), OBHS is provided by C&W escorting staff.

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

OBHS have been provided in 15 trains (14 through outsourcing and one train by depot)

iv) Nos of Mail/ Express train in which no staff from depot and

All major Mail/Express trains have been provided OBHS through


S.N Item Clause Observation OBHS through contract have been provided.

contract and escorting by depot.

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

Av PSI is 94.2%. System exists to verify PSI by depot and deduction has been made accordingly.

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

System to get feedback of cleanliness, linen quality and pest infestation of Mail/Express trains is not adequate. Regular feedback from CA (coach attendant) in standard format is not taken. However, Officers and supervisors have been deployed for on-board inspection to get the feedback of cleanliness, linen quality and pest infestation and OBHS performance.

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

Passenger complaints for last three years are as under:

Yr Pest/ rodent

Linen

Others

Total

09 -10

20 18 34 72

10-11

34 50 53 137

11-12

17 4 16 37

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.

Depot has awarded contract for mechanised cleaning of 4 PM trains only. Other trains are attended by depot. Mechanised cleaning equipments available in depot are not working. Cleaning through high pressure jet is available for Rajdhani Exp only.

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

FAC and composite are provided with upholstery. Carpets have been removed from coaches. Cleaning activity is being carried out through contract by a professional agency

30.6 Whether curtains are cleaned at prescribed interval of 15 days as per RB guidelines

Curtains are cleaned at one 15 days interval.

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

Blankets were cleaned at one month interval..

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.

Cleaning standard in Rajdhani Exp is satisfactory. For other trains, outside area and toilets cleaning needs improvement.



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

Depot has adopted collection and disposal of leftover food and refuses from pantry coaches and OBHS operated trains after arrival of train at station.

c) Sustainable garbage collection and disposal system

Yard cleaning and garbage disposal is carried out through contract. .

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

Drainage is not adequate. Water logging observed.

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

Periodic pest control treatment is being done through fogging machine. Cleanliness is being ensured in washing area.

f) Monitoring the functioning of OBHS and CTS scheme.

Functioning of OBHS is monitored. Officers and supervisors are carrying out on-board inspection to monitor performance of OBHS.

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.

Officers in SAG have been nominated at Zonal level under “OYTS”.

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.

Linens are cleaned through mechanised laundry. Depot has installed one mechanised laundry which cater requirement of 3500 packets per day. Depot has total requirements of 5,000 packets per day. Balance quality is washed through outsourcing in a mechanised laundry. 25% extra quantity is normally supplied in each coach. However, there is a space constraint for linen storage in ACCN coach of 2004 and earlier make. Regular condemnation is being done on condition / age basis and replenished with new linen.

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

One mechanised laundry has been commissioned at depot and in regular use since last 15 months. Total 3500 packets are washed in this laundry.

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

Packaging and storage is adequate. Servicing to linen is being done by coach attendant of Electrical department & Commercial department.



31 LHB coach attention:

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

Depot has total holding of 78 LHB coaches for Rajdhani service. IOH and POH attentions are given by C&W Workshop, Liluah. Periodic attentions (IOH / POH) as per RB’s guidelines are given. D2 Schedule (Monthly attention) and D3 Schedule (six monthly attentions) are given in rake. D3 schedule is not adequate as coach is not detached from rake for attention in sick-line.

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

Contract for disc brake (including air brake) attention in LHB coaches for KB makes and FTIL make brake system expired. Depot is carrying out maintenance attention of KB and FTIL make disc brake system through in-house. Population of KB and FT make disc brake system is as under KB make: 30 FTIL make: : 48 Attention for phonic wheel and speed sensor is given as per recommended frequency. Earthing device is attended through a contract on OEM and all earthing devises are in working condition. Depot is attending CDTS in-house. Spares are procured by depot from OEM. All CDTS are in working condition. Depot has rigged up a CDTS testing bench. Depot has received following dampers against indent placed on RCF as well as against warranty replacement: : Primary dampers: 140 Secondary vertical: 68 Lateral dampers: 50 Yaw dampers: 20

31.3 Wheel sets and CTRB attention at depot:

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

This is being followed. Supervisors are aware of various wheel defects. However, CMI –K003 guidelines have not been displayed on shop floor and sick line.



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


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


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 is taken for wheel sets with high temperature.

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

Rolling–in examination is being carried out at HWH station. Axle box temperature is measured with non-contact type temperature measuring equipment. Corrective action is taken for wheel sets with high temperature. 3 wheel sets of LHB coaches changed due to difference of temperature above 20

0C

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


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.

Traceability of wheel sets is ensured. Attention as stipulated is given for attention of CTRB at an interval of 1.2 Million Km. Wheel sets are cannibalised during maintenance and wheel sets sent to shop when due for CTRB attention (at 3 years interval). It is observed wheel sets with life of more than 2 years are in service at depot without UST of axle. As per guidelines circulated by DG/M&C/RDSO vide letter no. M&C/NDT/1/8, ICF axle need to be given UST at one year interval. No such guidelines have been circulated for LHB wheel sets. Presently LHB axle is attended for UST when wheel sets touch the workshop.

viii) Depot should not permit wheel sets with flaking in service. Adequate spare wheel sets are available in depot.

Wheel sets with flake is not permitted in service.

ix) Whenever coach is sent to shop for POH/IOH or non schedule attention, details of wheel sets with regard to CTRB attention

This is being ensured. Details provided to shop.


S.N Item Clause Observation 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.

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

With existing system, grease oozing out can be checked from front seal only when front cover is opened. This being checked during D2 schedule as front cover is opened for attention. For checking grease oozing out at rear grease seal, bottom control arm to be taken out. Checking of grease oozing out is not done for rear end seal at depot even in D3 schedule.

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

This is being eneured..

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

Mounting bolt is tightened regularly during PM.

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.


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.


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.


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


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

OEM guidelines This is being ensured.

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

All earthing devices are working. Earthing devices are maintained through AMC on OEM.


S.N Item Clause Observation fasteners, in case of theft attempts for non-ferrous items, mounted inside of axle box housing, can damage CTRB.

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

Earthing devices with connecting wire are available.

Junction box in broken/damaged condition.

Junction box is in good condition.

31.7 Disc brake attention: OEM guidelines

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

Brake pads are renewed on condition basis.

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

Brake callipers of KB and FTILO make are attended by depot as AMC with FTIL expired in Mar’11 and with KB expired in Mar’12.

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

Regular attention is given by depot through in-house. However, WSP is not working in 07 coaches. Availability of spares for disc brake system is hampering regular attention of disc brake system.

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

Depot is not aware of Guidelines issued by RDSO. However, at present coaches sent to and received from platform with full brake in working to avoid rolling of LHB rake.

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

This is being ensured. Length of buffer is maintained for ASF make and FTIL make as under: FTIL make – 650 mm ASF make – 635 mm


Annexure - I

Standard facilities in Carriage Maintenance Depots (Ref : CAMTECH Maintenance Manual for BG Coaches of ICF design,

1st 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

TKPR depot/Howrah is major depot as coach holding is 740 coaches.

Availability of Machinery and Plant

Description Minor

Depot

Medium

Depot

Major

Depot Observation

U/floor wheel lath - - 1 01 no available

Whiting jacks (5 Nos.) - 1 set 1 set 16 nos

EOT crane 20T - - 1 25 T carne is under installation.

Coach Shunter - 1 2 Available under traffic department.

Welding Plant 1 2 4 22 sets

Gas Cutting Equipment 1 2 2 Available

Vacuum Exhauster 1 2 2 Not required.

Air Compressor 30 cfm 1 2 2 360 CFM – 01 no.

500 CFM – 3 nos.

Portable Vacuum Testing Equipment - 1 1 Not required

Portable Air Compressor - - 1 Not available

2T Tram beam hoist 1 1 2 OH hoist (3T) – 1 no

Sewing machine - 1 1 02 nos

Truck 10T - - 1 Not available

Light Coml. Vehicle 1 1 1 Not available

Fork lift truck - - 1 04 nos

Lister truck 1 1 2 05nos

Car Washer - 1 1 Available


Description Minor

Depot

Medium

Depot

Major

Depot Observation

Portable Trolley Light 2 4 Not available

Cotton waste soaking plant 1 1 1 Not required.

Wood cutting saw machine - 1 1 Not required

Hand shearing machine - 1 1 Available

Portable Furnace 1 1 2 Available

Centre Lath - - 1 Available

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 Not available

Pressure Jet Cleaner 1 2 4 Not available

Tools

a. Pneumatic Hand Tools

i. Grinder 1 1 2 Not available

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 Available

ii. Drill - 1 1 Available

iii. Bolt Tightner - - 1 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 required.

v. DV Test Bench - 1 1 DV testing done at shop.

vi. Air brake single coach test rig - 1 1 RTR – 10 nos

SCTR – 04 nos

e. Office Equipment

i. Computer system 1 1 1 Available

ii. Plain Paper Copier 1 1 2 02

iii. Telefax 1 1 Available


Annexure - II

Emergency materials required for platform (C&W) office Sl. Items Required Observation

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

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

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

4 Draft link complete 2 sets Available

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

Modif.) 1 set each

Available

6 Anchor link with securing studs 1 set Available

7 Truss Bar Hanger with Pins & Cotters 2 sets Available

8 Bolster suspension Link (Stirrup Link) with Pins &

Stones 2 sets

Available

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

Pins 2 sets

Available

10 'O' Ring 2 nos. Available

11 Grease Servogen 4 kgs. Available

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

13 Angle cock 2 nos. Available

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

15 M.U. washer 10 nos. Available

16 Teflon Tape 1 no. Available

17 Portable Air Pressure Gauge 1 no. Available

18 Pressure Gauge BP & FP 2 each Available

19 BP & FP Air hose 2 each Available

20 Guard Emergency Application Valve 2 nos. Available

21 Wooden Plug (various sizes) 10 nos. Available

22 Wooden wedge 4 nos. Available

23 G.I. wire Adequ. Qt. Available

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


25 Push cock 5 nos. Available

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

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

28 Hydraulic Jacks 2 sets Available

Annexure – III

Details regarding coaching depot

Depot name and division:

1. Coach Holding

Mail/Expresses coaches with conventional coupling 604

Mail/Expresses coaches with CBC coupling NIL

Rajdhani/Shatabdi coaches (conv) 16

LHB coaches (Rajdhani/Duronto) 75

Hybrid coaches for Duronto 28

Double Decker 17

Grand Total 740

2. Maintenance attention of at depot

Mail Express trains






Total attention 26

3. Pit line attention

24 coach pit with catwalk and high pressure water

jet facility/watering facility at per CAMTECH’s

guidelines

3 CAMTECH design deep pits have been

constructed. However, high press jet facility has

not been provided.

24 coach pit facility with catwalk and washing

apron

04 nos

Less than 24 coach pit facility with catwalk and

washing apron

08 nos


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

NIL

03 nos.

Compressed air with reservoir and air

dryer/moisture trap facility with test rig (RTR)

4 nos compressors (500 CFM – 3 nos. and 360

CFM – 1 no.) are available with air dryer facility.

Facility for welding at Yard attention Facility for welding at Yard attention is available.

Night maintenance facility with overhead/pit light as

per CAMTECH’s guidelines

Deep pit lights are not working. Tube Lights are

provided under catwalk in 03 pits. Minor lamps are

used for pit attention. Portal lights have been

provided in 03 deep pits. Overhead lights have

been provided for general illumination. Night

maintenance facility is available in 03 pits only.

4. Sick line facility:

Coach lifting facility with overhead crane NIL

Coach lifting facility with JMP jack/hydraulic jack 16 nos.

Total coach accommodation

With pit attention Without pit attention

4 coach

6 coach

Facility for compressed air with test rig (SCTR) 04 nos.

Availability of hydrant water for overhead tank attention Water hydrant is available but testing

facility to carry out hydraulic testing of

repaired water tank is not available.

Welding facility Available

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

attention during night) as per CAMTECH’s guidelines: Deep pit lights are not working. Tube

Lights are provided under the catwalk. Minor lamps are used for pit attention. Portal lights have

been provided over 03 deep pits. Overhead lights have been provided for general illumination.

6. Availability of staff for coaching maintenance as per Yard stick:

Availability of manpower vis-à-vis requirement as per yard stick (bench marking norm) is as

under:

Activity Requirement as per Yard

stick (bens marking norm) Availability

Shortfall

/Excess

For cleaning activity 304 290 -14

For under-gear attention 354 335 -19

For sick-line activity 53 49 -4

For ancillary work 135 109 -26


7. Training status of supervisor and staff –

Overdue training for supervisors – 109 (Due: 116 & training given: 7) and overdue artisan for

refresher course - 81. Training of supervisor is given at STC/KPA. Depot has a good facility of

Divisional Training school for training of Artisan Staff.

8. Availability of critical/ safety stores and storage system: Safety list has been published by RB.

Depot is yet to reconcile safety store as per RB’s guidelines. Stock of safety items as per present list

is available. Stacking is adequate. There is crisis of composite brake block, secondary outer spring

for LHB coaches, speed sensor for LHB coaches and NFTC packing ring at Depot.

9. Availability of coaches as per rake link with maintenance spare: Against requirement of 613

coaches, total available stock is 740. (Maintenance spare as per yard stick is available).

10. Bottlenecks / limitations of system / depot:

Non standard Deep pits: Pits available were of non standard design without cat-walk. Only 03

deep pits of CAMTECH design with Catwalk have been constructed.

Inadequate spacing between two pits.

Curved Maintenance Line

Inadequate drainage system.

11. Safety performance record:

There is no derailment / accident on C&W account.

There is one en-route detachment of coach in 2011 -12.

12. Performance of critical spare:

Dampers fitted in LHB caches become defective due to oil leakage.

Rubber Bush fitted in damper cracked / perished during service.

quality audit report of coaching depot tikiapara, e...

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