Submitted By: Abhishek Mehta (191123) Anshul Singh (191129) Ashish Arora (191133) Kantika Gupta (191142)

Prashanth Prerepa (191157) Vineet Surana (191182)

Maintenance Management

Submitted To:

Prof. Neeta Gupta

@ Delhi Metro Rail Corporation

Table of Contents

About Delhi Metro Rail Corporation……………………………………………………………………..3

What is maintenance……………………………………………………………………………………………5

Maintenance at DMRC………………………………………………………………………………………….5

Maintenance of Consumables………………………………………………………………………………6

Rolling Stock…………….…………………………………………………………………………………….6

Signaling System…………………………………………………………………………………………….7

Station Maintenance……………………………………………………………………………………...7

Various Equipments used………………………………………………………………………………..8

Tracks……………………………………………………………………………………………………………..9

Work in Progress…………………………………………………………………………………………….9

Manpower Maintenance……………………………………………………………………………………10

Hierarchy/Reporting System…………………………………………………………………………..10

Training and Development..........…………………………………………………………………….11

Security……………………………………………………………………………………………………………11

Cost of Maintenance………………………………………………………………………………………….12

Emergency/Disaster Management……………………………………………………………………..13

Conclusion…………………………………………………………………………………….....……..………..14

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ACKNOWLEDGEMENT

We wish to express our sincere gratitude to all those people who have been associated with

this project and have helped us with it and made it a worthwhile experience for us.

We express our thanks to Prof. Neeta Gupta, who gave us this opportunity to learn the

subject in a practical approach and gave us valuable suggestions regarding the project

report.

Date: 09th March’2011

Group Members:

Abhishek Mehta (191123)

Anshul Singh (191129)

Ashish Arora (191133)

Kantika Gupta (191142)

Prashanth Prerepa (191157)

Vineet Surana (191182)

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About Delhi Metro Rail CooperationFor implementation and subsequent operation of Delhi MRTS (Mass Rapid Transit System),

a company under the name DELHI METRO RAIL CORPORATION (DMRC) was registered on

03-05-95 under the Companies Act, 1956.

Delhi Metro is a world-class metro. To ensure reliability and safety in train operations, it is

equipped with the most modern communication and train control system. It has state-of-

art air-conditioned coaches. Ticketing and passenger control are through Automatic Fare

Collection System, which is introduced in the country for the first time. Travelling in Delhi

Metro is a pleasure with trains ultimately available at three minutes frequency. Entries and

exits to metro stations are controlled by flap-doors operated by 'smart-cards' and contact

less tokens. For convenience of commuters, adequate number of escalators are installed at

metro stations.

Unique feature of Delhi Metro is its integration with other modes of public transport,

enabling the commuters to conveniently interchange from one mode to another. To

increase ridership of Delhi Metro, feeder buses for metro stations are Operating. In short,

Delhi Metro is a trendsetter for such systems in other cities of the country and in the South

Asian region.

Need For MRTS

As cities grow in size, the number of vehicular trips on road system goes up. This

necessitates a pragmatic policy shift to discourage private modes and encourage public

transport once the level of traffic along any travel corridor in one direction exceeds 20,000

persons per hour.

Introduction of a rail based (MRTS) Mass Rapid Transit System is called for. Mass Rapid

Transit Systems are capital intensive and have long gestation period. It has been observed

that in developed countries, planning for mass transit system starts when city population

size exceeds 1 million; the system is in position by the time the city population is 2 to 3

million and once the population exceeds 4 million or so, planned extensions to the Mass

Rapid Transit Systems is vigorously taken up. In developing countries including India,

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because of paucity of funds planning and implementation of rail based Mass Rapid Transit

Systems has been lagging far behind the requirements.

Delhi has experienced phenomenal growth in population in the last few decades. Its

population has increased from 57 lakhs in 1981 to 162 lakhs in 2006 and is poised to reach

190 lakhs by the year 2011. For want of an efficient mass transport system, the number of

motor vehicles has increased from 5.4 lakhs in 1981 to 51 lakhs in 2007 and is increasing

at the rate of 6.21 per annum. The number of motor vehicles in Delhi is now more than that

of Mumbai, Calcutta, Chennai put together. The result is extreme congestion on Delhi roads,

ever slowing speeds, increase in road accidents fuel wastage and environmental pollution

with motorized vehicles alone contributing to about two thirds of the atmospheric

pollution.

To rectify this situation the Government of India and the Government of National Capital

Territory of Delhi, in equal partnership have set up a company named Delhi Metro Rail

Corporation Ltd. under the Companies Act,1956 which has (already commissioned a 65.10

kms route in Phase-I and is proceeding ahead with another 121 kms in Phase –II).

Physical construction work on the Delhi Metro started on October 1, 1998. The first line

opened on December 24, 2002 and the entire Phase I of the project was completed in

December 2005, on budget and almost three years ahead of schedule, an achievement

described as "nothing short of a miracle"

The entire work of length approximately 413.83 km, planned so far is divided into four

parts:

Delhi Metro lines in operation

Line First Operational

Last Extension

Stations Length(Km)

Terminals Rolling stock

RED LINE December 24, 2002

June 4, 2008

21 25.15 Dilshad Garden to Rithala

23 Trains

YELLOW LINE

December 20, 2004

September 3, 2010

34 44.65 Jahangirpuri to HUDA City Centre

45 trains

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BLUE LINE

December 31, 2005

October 30, 2010

44 50 Noida City Centre to Dwarka Sector 21

59 trains

January 8, 2010

_ 6 6.25 Yamuna Bank to Anand Vihar

GREEN LINE

April 3, 2010

_ 15 18.46 Inderlok to Munirka

13 Trains

VIOLET LINE

October 3, 2010

January 14, 2011

15 20.04 Central Secretariat to Badarpur

29 Trains

AIRPORT EXPRESS

February 23, 2011

_ 6 22.70 New Delhi to Dwarka Sector 21

8 Trains

Routes under construction

Phase II consists of 127 km (79 miles) of new rail, of which the following sections are under

construction. This phase has completion deadline of 2010. Overall progress of Phase-II has

been 37% as of July, 2009.

Planned

Opening DateRoute Terminals Length(km) Stations

June 2011 Blue LineAnand Vihar to

Vaishali (Ghaziabad)2.5 2

June 2011 Green LineKirti Nagar to Ashok

Park Main3.32 2

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Future extensions

Several extensions to the Delhi Metro network have been planned.

Phase III

Routes within Delhi

Phase III, tentatively composed of four routes covering 105 Kilometres, has a 2015

deadline. The following routes have received Cabinet clearance and are expected to

commence construction by the end of 2010:

Central Secretariat to Kashmiri Gate (9.8 km) - Violet Line extension

Mukundpur to Siv Vihar (via- Dhaula Kuan, Sarai Kale Khan , Anand Vihar Welcome)

- New line following Inner Ring Road (LINE-7)

Jahangirpuri to Badali (3.4 km) - Yellow Line extension

Janakpuri(west) to Kalindi Kunj - line-8

Routes beyond Delhi border

In addition, a 13.8 km (8.6 mi) long extension of the Violet Line from Badarpur into

Faridabad in neighbouring Haryana at a cost of 2,533 crore has received budgetary and

other clearances, and construction has already begin since October 2010.

Phase IV

Phase IV has a 2020 deadline, and tentatively includes further extensions to Sonia Vihar,

Reola Khanpur, Palam, Najafgarh, Ghazipur, Noida Sector 62, Gurgaon and Faridabad,

having a total length of 108.5 km. Apart from these lines in Phases I to IV, plans have been

mooted to construct a new line from Noida Sector 62 to Greater Noida which will intersect

Indraprastha – Noida Sector 32 line. The Ghaziabad Development Authority (GDA) is

planning to extend Delhi Metro lines deeper into Ghaziabad in three phases, including the

extension of the Blue Line from Anand Vihar to Vaishali, and subsequently to Mehrauli via

Indirapuram, as well as the extension of the Red Line from Dilshad Garden to the new

Ghaziabad bus stand. The independently operated Gurgaon Metro, work on which is going

on and has a deadline of 2013, will also interchange with the Delhi Metro.

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What is Maintenance?The term ‘maintenance’ means to keep the equipment in operational condition or repair it

to its operational mode. Main objective of the maintenance is to have increased availability

of production systems, with increased safety and optimized cost. Maintenance

management involves managing the functions of maintenance.

In broader terms maintenance can be defined as an administrative, financial,

and technical framework for assessing and planning maintenance operations on a

scheduled basis.

Maintenance at DMRCAlmost all the construction activities are outsourced by DMRC and the lone thing they take

care of is, Maintenance.

Maintenance Goal: To provide 99.5% punctuality to the customers

This goal cannot be fulfilled without a good and a formidable maintenance management

system in place. Broadly, there are two kinds of maintenance activities carried out by the

company:

1. Maintenance of Consumables

2. Labor Maintenance

Most of the maintenance activities are planned in DMRC and there are a very few

unplanned activities (only in case of emergency).

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Maintenance of ConsumablesConsumables include all the resources that DMRC has and maintains except labor that

comes under a separate head of maintenance.

These are some of the important consumables at DMRC:

1. Rolling Stock

a. Manufacturers: The first wave of rolling stock was manufactured by a

consortium comprising Hyundai Rotem, Mitsubishi Corporation and Mitsubishi

Electric Corporation. Initial sets were built by ROTEM in South Korea, with later

examples completed in India by public sector undertaking Bharat Earth Movers

Limited (BEML). BEML is also responsible for the manufacturing coaches under

technology transfer agreement. 

Capacity: Delhi Metro has a fleet of 280 coaches, which DMRC runs as 70 trains

every day. Each train can accommodate about 1,500 people, 240 seated.

b. Number of trains: Train depots are located at Khyber Pass, Najafgarh, Shastri

Park and Yamuna Bank. In the depot we visited, there were 15 trains with 13

running and 2 as backup. In case a train breaks down, it returns to the depot and

the backup train replaces it.

c. Daily Checks: The first train starts at 0600 hours in the morning. At 0500 hours,

a train leaves the depot to make a round trip. During that one hour, all the

equipment, breaks, air-conditioning, signaling, tracks and all other facilities and

technologies attached to the smooth running of Metro are checked. The last train

parks itself in the depot at 2300 hours and they have 6 hours to carry all the

maintenance and repair work if at all there is any.

d. Washing: Every third day, the trains are cleaned in the automatic washing

equipment (AWE). It takes 22 minutes to clean the whole train.

e. Facilities: The coaches are fully air conditioned, equipped with automatic doors,

microprocessor controlled brakes and secondary air suspension. The new

coaches possess several improved features like CCTV cameras with eight-hour

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backup for added security, charging points in all coaches for cell phones and

laptops, improved air conditioning to provide a temperature of 25 degrees

Celsius even in packed conditions and heaters for winter. All these are checked

during the 1 hour test run in the morning

2. Signaling System

A surveillance control system called SCADA (Provided by Korea based company

Bombardier) is used by DMRC to take care of the signaling activities involved in the

running of Metro. It is a centralized automatic control system comprising:

a. Automatic Train Operation (ATO): The movement of the train, starting,

stopping, turning on/off the air-conditioning, Wi-Fi enabling, control of doors

and the functioning of the whole train can be controlled from this control centre

in Shastri Park.

b. Automatic train protection (ATP): The control centre gets to know of any

irregularity in the operation of any train. For example, if a train running on line 1

has a problem with two of its doors, then the ATP can permanently shut those

doors till they are repaired. Similarly, they also take care of the timings of the

trains and the minimum distance to be maintained in order to avoid any

accident.

c. Automatic Train Signaling (ATS): There are two Overhead cables running

across the whole circuit that provide signals to the control centre about all the

train in operation.

This strong Signaling system is contributing is contributing to the success of Delhi

Metro in a big way.

3. Station maintenance

There are 4 major maintenance activities carried out by the staff on the stations

a. Electricity: Each station has a separate electricity substation that provides

electricity. In case of a power failure, the load is shifted to the backup

automatically so that the operations do not stop.

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b. Signaling: Each station also have a signaling substation giving them the

control of the trains running on that line. The control is limited.

c. Facilities: Maintenance of facilities like lifts, escalators etc are headache of

the station staff.

d. AFC (Automatic Fare Collection): The AFC machines are maintained by the

station staff headed by the station manager. The control of the system is with

the respective stations and the central control unit at Shastri Park. This AFC

equipment helps the authority forecast the passenger flow during the day

and the time of the year.

4. Various Equipments Used:

Here is a list of some important equipment we saw inside the depot:

a. Automatic Washing Equipment (AWE)

Trains are washed every second or third day using this setup. It takes exact

22 minutes to clean the train. There is one AWE per depot.

b. Automatic Train Lifters (ATL)

These are used to lift the train up to a height 14.5 feet, so that

repair/maintenance work can be carried out easily. There are two ATLs per

depot.

c. Road-cum-Rail moving vehicles (RRV)

There are no electric lines inside the depot. Therefore, if any repair work is to

be carried out, the train has to be pulled using these RRVs into the depot on

to the ATL. This vehicle can move on road as well as on the track.

d. Maintenance lines

The depot we visited had 3 maintenance lines where the train can be parked

and the work can be done by moving down the tunnel beneath the train. It is

like using an ATL, but here, land is lowered, instead of lifting the train.

e. Automatic Wheel Balancers

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Once in two days each train runs through the automatic wheel balancing

equipment wherein, the wheels of the coach are smoothened and polished.

Each depot as one such equipment

5. Tracks

The tracks are maintained by DMRC technicians. They are checked for faults every

day, after 11:00PM. The current track length is 96.1 Km, it would be 186.19 Km by

March’2011 and 413.8 Km on completion of the project (by 2021)

6. Work in Progress

All the construction work at DMRC is outsourced to contractors, and the company

solely maintains the infrastructure.

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Manpower MaintenanceManpower maintenance contributes to almost 70% of the total maintenance cost.

1. Hierarchy/Reporting

DMRC is known to have a very lean hierarchy. There are only two departments in

the company:

a. Project Organization

b. Operations and Maintenance (O&M)

Each of these units has a separate Director. Below the Director, are the General

Managers. There are separate GMs for separate operations of the company. E.g. GM,

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Managing Director

Director(Operations)

GMGM

DGMDGM

AMAM

SE & JESE & JE

Technicians Technicians

Director(Project Organization)

Chairman

Signaling; GM, repairs; GM, Maintenance etc. Below the GM are the Divisional

General Managers (DGM), who are specific to a single phase. Then comes the

Assistant Managers (AM) that are responsible for specific operation of a particular

station only. After that comes the Junior engineers (JE) and the Section Engineers

(SE) who look after the technical side of the operations. And at the bottom of the

hierarchy are the Technicians, who do the technical jobs.

Each employee has to make a DPR (Detailed project Report) and submit it to the

supervisor. It contains the job assigned and the completion status. Every Monday,

the GMs meet to review the progress and set new targets.

The stress is on adherence to schedule.

2. Training and Development

A training school for Metro Operating and Maintenance Staff has been set up at

Shastri Park. Under an agreement with the Hong Kong Metro Railway, 60 employees

of DMRC have been trained on their system. These employees after completing their

training have returned and have trained the staff locally recruited for Delhi Metro.

Regular training is held for new recruits through induction programmes apart from

refresher training for experienced employees in all categories of staff including

Train operators, Station controllers, maintenance Staff etc.

Here all the employees undergo training once a year so that they could be updated

with the latest advancement in technology and adhere to changes.

This ISO 9001 certified school also has a train simulation system to train the drivers.

3. Security:

The sources of the tight security at all stations are:

a. CISF

b. Security Managers employed by DMRC – to assist customers on stations. For eg.

Keeping commuters behind the yellow line etc

c. Security Agencies – Group 4: This company provides security guards to DMRC

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Cost of MaintenanceThere are only two major types of cost:

1. Consumables

This contributes almost 30% of the total maintenance cost. It includes electricity,

trains, equipments, signaling, various facilities etc.

2. Manpower

The company has 45 persons per kilometer, which excludes the contracted labor. If

we include that, the total manpower it goes up to 150 persons per kilometer.

This contributes to almost 70% of the total Maintenance expenditure.

Maintenance Cost (in Rs. Crore)Year O&M Year O&M Year O&M2005 312.3 2017 1048.4 2029 2014.92006 325.3 2018 1098.1 2030 2125.52007 338.7 2019 1150.7 2031 2462.82008 352.7 2020 1212.7 2032 2604.22009 367.4 2021 1376.3 2033 2756.22010 782.2 2022 1437.4 2034 2919.82011 800.6 2023 1503.2 2035 3095.82012 836.6 2024 1573.8 2036 3285.22013 874.5 2025 1649.8 2037 3489.12014 914.5 2026 1731.6 2038 3708.62015 956.8 2027 1819.5 2039 3944.92016 1001.3 2028 1914.1 2040 4199.3

We can see that the maintenance cost for DMRC is very high and is increasing at a rate of

9%. So a proper Maintenance procedure is a must and the authorities have done a good job

at that.

There is another type of unplanned cost: Downtime Cost. If Metro operations stop for one

day, the company incurs a loss of 25 Crores. This excludes the loss of tickets selling

revenue.

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Emergency Situation/Disaster Management

a. Breakdown: In case the train breaks down in the middle of the journey, the

passengers are guided safely to the platform and the train is brought back to the

depot for repair. This train is replaced by the backup train so that the waiting time

due to one less train on the track is avoided.

b. Terrorist Attack: They have a full Disaster Management team constituting

personals from different Government security groups like ATS. These have their

regular drill and will reach the spot in less than 15 minutes of the attack. Also, there

are 1200 CCTVs installed in the new trains and stations.

c. Fire: Sprinklers and fire alarms are installed in the trains and stations. DMRC often

organizes fire drills in schools to educate children about the use of fire

extinguishers. Intercom is provided in the trains, which connects the commuter

directly to the driver of the train.

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ConclusionThe estimated cost of the complete 413Km project is close to 25000 Crores and an equal

amount goes into the maintenance of the existing infrastructure. Therefore, maintenance

plays a huge role in the success of Delhi Metro. At present, the authorities have lived up to

their promise of 99.5% punctuality and according to a survey by students at MDI, Gurgaon,

92.7% of NCR respondents think that Delhi Metro is a boon to the environment and the

society.

The question to be answered is, that is the current maintenance levels sufficient to

maintain the present commuter satisfaction, once the Metro project is completed. Our

group feels that, yes, they have a pretty robust maintenance system in place that will suffice

in the future.

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