Quality Audit report Of Coaching Depot Secunderabad, SC ...rdso.indianrailways.gov.in/works/uploads/File... · on divisions where rake has been based for primary maintenance. 112(a)

Quality Audit report

Of

Coaching Depot

Secunderabad, SC Rly

Report no. 48/2012

APRIL 2012

(Audit is done by QA Mech Dte of RDSO)

Co-ordinated by

Quality Assurance (Mechanical) Directorate

Research Designs & Standards Organisation Manak Nagar, Lucknow - 226011

Page 1 of 37 Coaching depot-SC, SC Rly April 2012

Quality audit Report of Secunderabad Coaching depot, S C Railway

1.0 Introduction

Based on Instructions issued by AM (PU), Railway Board. Quality audit of

coaching depot/workshops has been done by Director(Motive Power)/RDSO.

1.1 Audit team – Sri Anil Kumar, Director(Motive Power)/RDSO

1.2 Dates of Audit - 25.04.2012

1.3 Escorting Officials - Sri S. Siddheswara Rao CDO/SC/SCR, Sri Wilson.

Sullad SSE/C&W/SC, Sri A. Gangaraju SSE/OBHS/SC, Sri Rasool Basha

SSE/MCC/SC, Sri S K Hira SSE/BD/SC, Sri K.Gangaraju Saheb

SSE/IOH/SC

1.4 Scope of Audit - Pit lines, IOH shed, sick line, stores, platforms, linen stores,

Rolling in/Rolling out points, pit lines, Mechanised laundry.

2.0 Brief about Secunderabad Coaching depot

SC Coaching depot with a holding of 740 coaches is the major coaching

depot of South Central Railway. The depot is dealing with multi stocks like

Conventional ICF/RCF coaches, LHB Hybrid coaches with air springs, LHB

Fiat coaches with disc brakes, Garibrath coaches and VP loading.

The depot is having multi activities like primary maintenance, secondary

maintenance, turn round maintenance, pass through train examination, Break

down (SPART, SPMRV, 140T crane), Pit Wheel lathe, Mechanised Laundry,

Linen management including washing and distribution, Maintenance of

Inspection carriages, OBHS etc.

IOH of coaches is attended in the Mechanical sick line and Electrical repairs

are attended in electrical sick line.

6 pit lines and 8 stabling lines in two Grids(Lower Yard & Washing siding)

comprising Grid 1(Lower yard) with 4 pit lines and 6 stabling lines and Grid 2

(Washing siding) with 2 pit lines and 4 stabling lines.

During the audit infrastructure availability in coaching depot, system of

working, processes and procedures being adopted, record keeping,

monitoring and supervision, planning etc. were studied.


3.0 Strengths

3.1 A system has been introduced for officer/supervisor ownership and joint rake

checking for pest control on specific rakes after treatment by Mechanical and

commercial departments using check lists.

3.2 The depot is having a work force with multi skills to adopt to new

technologies like LHB Hybrid with Air springs, LHB Fiat with disc Brake and

WSP system.

3.3 Record keeping of depot is very good. 100 days sick marking, coach failure

Reports, Bogie Lorry Movements, warranty claims records, DV Failure

Reports Coil Spring failure and CMT Analysis, History and schedule cards, ,

Pest complaints OBHS feedback, Mechanized cleaning contract Feedback ,

LINEN Complaints is maintained systematically.

3.4 With proper planning and systematic working and with good liaison with

shops, the depot is able to wipe out all the overdue IOH coaches and at

present no coach is overdue for IOH.

3.5 In house maintenance of LED destination boards has been developed.

3.6 Effective out sourcing of Non – core activities

- Buffing of Stainless Steel fittings in coaches - Curtain washing and replacement in AC coaches - Exterior Painting of coaches during IOH Schedule - Stainless steel panelling of Pantry cars

3.7 Materials management

a. In store the materials are stacked neatly with labels displaying the PL numbers.

b. Adequate stock of imprest and non-imprest items is maintained. c. As the coach holding is 740 coaches, the depot imprest cash has been

increased to Rs.50,000/. In case of emergency, the materials are purchased through imprest cash and ensured that the materials are available all the time.

3.8 One Ton Mechanised Laundry was set up and the bedroll turned out from laundry are distributed in prestigious trains like 12220 SC – LTT Duronto Exp., 12740 SC – VSKP Exp. And 12285 SC – NZM Exp.


4.0 Weaknesses

4.1 Rakes are not maintained in one Hook.

In washing siding, the pitline capacity is of 17 and 16 coaches only. The

trains maintained here are having composition more than 17 coaches and the

rakes are placed in two hooks for maintenance.

- 17015/17016 Visakha Exp. (20) - 12763/12764 Padmavathi Exp. (19) - 12732/12731 Tirupati Exp. (19) - 17038/17037 Bikaner Exp. (21) - 12752/12751 Manuguru Exp. (18)

4.2 Pit lines

4.2.1 The pit lines in washing siding are of old design and at many places catwalk

is in damaged condition. The gap between the catwalk and the coach body

is narrow making it difficult for the staff to examine the rakes. No lighting

arrangement is available in pit lines and yard for night examination.

4.2.2 In Lower yard L4 and L5 pit lines are not having pit line lighting. Every day

four trains are maintained during the night shift.

4.3 Standby Diesel driven compressor is not available. In case of power failure,

the rakes are tested with shunting locos

4.4 Recommended population of Mechanical and operating spare coaches is not

available.

4.5 Scarcity of water during summer season has been the major concern

affecting the cleanliness of coaches interior & exterior.


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)

S.No. Item Clause Observations 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

Periodical detachment is being ensured and sent to designated workshops only. Coach holding – 740 Over Due POH (3/12) Nil Due POH (4/12) - 5 Coaches

2. Maintenance schedules to be followed in coaching depots

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

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

Being followed as per the guidelines and revised periodicities given in the Bd letter.

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

Coach holding – 740 Overdue Sch A :-Nil-

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

- Nil – (items prescribed in the B schedules like testing of PEASD, painting of lavatories from inside, thorough inspection and repairs of U/G and touching up of painted portion, if faded etc are being attending in A schedule.

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

Coach Category

Periodicity

New coach at interval of 12 months

in Depot

Rajdhani Satabdi (Conv)

at interval of 9 months in workshop

Mail / Express at interval of 9 months in

depot

Passenger at interval of 9 months in

depot

Other OCVs at interval of 12 months

in depot

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

Coach holding – 740 Overdue IOH – -Nil- (without considering the tolerance period of 30 days) This Depot is detaching IOH due coaches for service as and when they complete 9 months without considering tolerance period of 30 days.

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 Being ensured to all PM coaches and Schedules are being attending for the other base coaches as when due if they are taken for maintenance in this Depot.


S.No. Item Clause Observations 7. Examination of originating trains: 107 a of Chg. Manual

At present this depot is primarily maintaining 17 Exp/SF. (list of trains is Enclosed Annexure-A)

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

107 a (i) of Chg. Manual

Being ensured

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

107 b of Chg. Manual

Rolling in examination is conducting for all terminating, Turn round and pass through trains. (List of Trains enclosed as Annexure-A,B,C)

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

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

Yes, there is no obstruction for view of under gear examination from both sides.

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

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

Yes the adequate space is available.

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 The rolling in and rolling out examination is conducting for all the pass through trains.

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 Temperature of all axle boxes All the PM , terminating trains and pass through trains which are having 10 mins halt are measuring with non contact thermometers simultaneously in both directions and at both right and left hand side of the coach.

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

RPC-IV is being followed and clear maintenance timings of six hours in pit is ensuring for all PM trains. However, the trains which are stabling more than 4 hours on PFs are unable to take in to pit/washing lines in view of shortage of pit occupation.

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

Ensuring approved mandatory conditions at other end before starting new trains. However, there are five trains which are getting OEA at SC are having less than minimum 2 Hrs required for maintenance. ( Annexure – D)

9.1.1 Primary End

i) The brake gearing should be properly adjusted

including the slack adjuster ‘A’ dimension &

the brake cylinder stroke to ensure 100%

brake power

-do- Being followed.

ii) Brake blocks should be changed in bogie sets only

-do- In all the coaches brake blocks are changing in bogie sets only for all PM trains.

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

-do- All the amenity fittings are provided and the same is recorded in RS-72 register for all


S.No. Item Clause Observations

PM trains. iv) Intensive cleaning of coach toilets and

lavatory. -do- At present this depot is

outsourced this activity to outside agency and the same is ensured by super checks.

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

-do- Clear maintenance time of 6 hours on the pit is taken 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- At present only four pit lines are having HP jet cleaning facilities and three pit lines are having testing equipment. Out of 6 pit lines one is with CAMTECH design with catwalk, 5 pit line with conventional pit line with catwalk

vii) Adequate gang strength with proper supervision

-do- Adequate Group C Staff are not available for maintenance as per yard stick of 0.9 for mail/express and 1.1 for Superfast trains

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- The rakes for which the lie over is more than 2 hours, the rakes are locked.

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

-do- For OEA maintenance, there is no C& W storage room for keeping Coach materials for attention to 21 OEM trains dealt on Platforms

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- The joint safety certificates are existing for all trains maintained at this depot.

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

All the trains are having maintenance time of 6 Hrs.(Pit occupation chart enclosed)

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

At presently all the OEM/Turn round trains are cleaning and watering for nominated trains. But time is not sufficient for cleaning for some of the trains.

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 At present this Mechanized Cleaning activity is out sourced to outside agency by using specified cleaning chemicals which was approved by CME specified in the agreement.

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 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

109 (b)(i) of Chg.Manual All the washing line, pit lines, sick lines are properly secured by providing danger boards and skids whenever the train is in occupation.

12.3 External cleaning /washing: 109 (b) of Chg.Manual At present this activity is out


S.No. Item Clause Observations Check that guidelines as detailed in CAMTECH manual are being followed.

sourced to outside agency and ensured.

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

109 (c) of Chg.Manual At present this activity is out sourced to outside agency and ensured

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 At present this activity is out sourced to outside agency and ensured

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

109(e) of Chg.Manual At present this activity is out sourced to outside agency and ensured

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 All the buffers plungers are properly scrapped, cleaned and oiled with recommended oils

(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 All the screw couplings are properly scrapped, cleaned and oiled with recommended oils

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 At present only four pit lines are having 24 coaches capacity. Out of 6 pit lines one is with CAMTECH design with catwalk, 5 pit lines are conventional with catwalk

(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 At present only four pit lines are having HP jet cleaning facility. Laying of high pressure jet pipe lines for the remaining pit lines is in progress and the same will be completed within this week.

(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 Available.

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

110(a)(iv) of Chg.Manual Adequate air brake maintenance and testing equipment are available totally five rake test rigs and two single car test rigs are available with all maintenance spares

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 All the PM coaches are with air brake twin pipe graduated release system

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

110(b)(ii) of Chg.Manual All the PM coaches are with enhanced capacity draw gear and screw coupling of 75 T capacity

13.3 Maintenance practices and system related requirements

110(c) of Chg.Manual

i) The integrity of the rakes to be maintained. 110(c)(i) of Chg.Manual Being ensured


S.No. Item Clause Observations ii) Primary maintenance of the rake should be

done in one hook without splitting 110(c)(ii) of Chg.Manual At present all the PM trains

maintained in Lower yard are maintained with one hook without splitting. However the rakes maintained in washing siding are split in two parts as the pit lines capacity is 17 and 16 coaches only. The following trains are maintained in washing siding

1. 17015/17016 Visakha Exp.(20)(Daily)

2. 12763/12764 Padmavathi Exp.(19) (Sun, Tue, Thu, Fri, Sat)

3. 127321/12732 Tirupati Exp.(19) (Mon, Wed)

4. 12751/12752 Manuguru Exp.(18) (Mon, Wed, Fri)

5. 17037/17038 Bikaner Exp(21) (Tue, Wed)

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

110(c)(iii) of Chg.Manual Minimum maintenance time of 6 hours on pitline is ensured during Primary maintenance

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 Being followed

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

110(c)(v) of Chg.Manual At present all the PM rakes are being tested with leakage test gadget and ensuring the rakes within the prescribed rate of 0.2kg/cm

2 (0.6 kg/cm

2 in 3 mins).

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

110(c)(vi) of Chg.Manual The proportionate brake system i.e., A-9 handle is available in Rake Test Rig.

vii) Provision of audio visual alarm system on the locomotive

110(c)(vii) of Chg.Manual Not applicable .

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

111(f)(i) of Chg.Manual At present this depot is outsourced the activity of refilling of Fire extinguishers through outside agency and all the fire extinguishers’ due dates are within validity date.

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

Provision of Prescribed quantity of DCP type fire extinguisher are ensuring in all the SLRs, AC coaches, Pantry cars

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,

111(g)(i) of Chg.Manual Being followed


S.No. Item Clause Observations wooden wedges/skids and stretcher are to be provided.

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 This depot is a nominated for en-route watering. List of pass through trains enclosed.

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 All the PM trains are issuing DRS card to the GDR duly endorsing by maintenance Engineer(C&W). .

(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 Joint check by TXR along with RPF is being done on arrival of the train. RS 18 is prepared and it is jointly signed by TXR, RPF.

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 The daily coach movements and sick marking are entered in software developed in MS access database and history cards are maintained in the system.

(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 Pertains to workshop

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 All the primary maintained rakes are examined as per the guidelines issued by Hqrs.

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

113(b) of Chg.Manual 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 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 Being followed.

19.5 The following items of undergear components 113 (e) of Chg.Manual


S.No. Item Clause Observations should, however, be specially examined and attended to:-

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

113 (e) (i) of Chg.Manual

No Rajadhani rake is maintained at SC. For other rakes oil level of 40mm is maintained in dashpot by replenishing on every month.

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

113(e)(ii) of Chg.Manual All the wheels of PM trains are checked by tyre defect gauge and comb gauge for checking the thickness of flanges.

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 Piston stroke of 32 mm is ensuring to all BMBC coaches.

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 Being ensured

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

iii) Door lock handles 113(f)(iii) of Chg.Manual Being ensured iv) Tower bolts 113(f)(iv) of Chg.Manual Being ensured

v) Window shutters should neither be tight nor loose

113(f)(v) of Chg.Manual Being ensured

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

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

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

113(f)(viii) of Chg.Manual Being ensured

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

113(f)(x) of Chg.Manual Being ensured

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

113(f)(xi) of Chg.Manual Being ensured

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

113(f)(xii) of Chg.Manual Being ensured

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

113(h) of Chg.Manual Being maintained

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

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

114 (a) of Chg.Manual Being followed

ii. Brake system maintenance 114(b) of Chg.Manual Being maintained


S.No. Item Clause Observations Air brake system (bogie mounted) A schedule maintenance as per air brake chapter

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

114(c) of Chg.Manual Being done

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 Items prescribed in the B schedules like testing of PEASD, painting of lavatories from inside, and touching up of painted portion, if faded etc are being attending in A schedule.

ii. The specified items of work should be attended.

115(b) of Being done

iii. Brake system maintenance

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

Chg.Manual Being done

iv. Other assembly maintenance

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

115(b)(i) of Chg.Manual

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

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

c. Thorough inspection and repairs of brake gear components.

115(b)(iv) of Chg.Manual Being attended during ‘A’ schedule itself

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

115(b)(v) of Chg.Manual Being attended during ‘A’ schedule itself

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

115(b)(vi) of Chg.Manual Being attended during ‘A’ schedule itself

22. IOH attention

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

Over hauled bogie along with wheel sets are being received from POH shops

22.1 Periodicity of IOH attention:

Coach Category

Periodicity

New coach at interval of 12 months in Depot

Rajdhani Satabdi (Conv)

at interval of 9 months in workshop

Mail / Express at interval of 9

months in depot

Passenger at interval of 9

months in depot

Other OCVs at interval of 12 months in depot

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

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

Periodicity as prescribed is being followed for all categories of coaches.

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

All the IOH due coaches are being detached from the rakes and attending IOH duly replacing bogies on unit exchange basis.


S.No. Item Clause Observations 22.3 Brake system : ‘C’ schedule maintenance

(IOH) as per para 426 of air brake chapter. 117(a)(i) of Chg.Manual Brake system being checked with

single car test rig. 22.4 Thoroughly clean Dirt collector filter in

kerosene or replace on condition basis. 117(a)(vii) of Chg.Manual Being attended during IOH

without fail. 22.5 Other assemblies maintenance

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

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 Guidelines received vide Rly Bd Lr.no.2007/M(C)/141/1, dt.26.09.08 are being followed and all the bogies of exp are replacing as unit exchange for exp and other coaches as specified.

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

117(a)(iii) of Chg.Manual All the IOH coaches are being painted with satin blue for exterior and with smoke gray for interior of the coach.

22.8 Polishing of the polished surfaces. 117(a)(iv) of Chg.Manual This activity is carried out on monthly basis.

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 The thorough examination of shock absorbers is being ensured during the IOH and same is being replaced with new if found defective.

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 All the items are attending thoroughly during IOH.

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

117(a)(vii) of Chg.Manual All the items are attending thoroughly during IOH.

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 All the items are attending thoroughly during IOH.

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 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 All the items are attending thoroughly during IOH.

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

117 (d) of Chg.Manual All the vulnerable areas for corrosion need to be focused (Being followed.)

22.16 Special attention should be taken for the following:-

117(e) of Chg.Manual

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

117(e)(i) of Chg.Manual All the items are attending thoroughly during IOH.


S.No. Item Clause Observations II). Drain holes provided in the trough floors

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

117(e)(ii) of Chg.Manual All the items are attending thoroughly during IOH.

III) A register should be maintained on 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 Schedule ‘A’ cards are maintaining and for IOH checklist is maintaining for all PM coaches.

22.17

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

118 (b) of Chg.Manual Not applicable

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

118(c) of Chg.Manual Not applicable

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.

The total linen management activity was taken over from commercial department on 01.06.10. At presently the washing of linen is out sourced to outside agency and the storage and supply in maintaining departmentally and distribution of linen kits in train is also out sourced. However, Inadequate linen storage space at PF 1. At least one more room at PF 1 is required

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 being carried out by Sr.Supervisors on 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.

Super checks for new linen is being carried out by Sr.Supervisors whenever receiving a new lot from MFT/SC

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

One technician is nominated to monitor the washing activities at Washing Plant (Laundry) and 20% checks was conducting by CDO and SSEs and penalties are deducting from the running bills.

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

Sufficient buffer stock for 2 days is kept as spare.

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

At present all the linen items are stamped with introduction date and all over due linen is segregated and condemned as per norms.

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

Standing committee consisting of ACM/SC, CDO/HYB, and ADFM/SC are the nominated


S.No. Item Clause Observations

committee members for condemnation of linen on condition basis. ( Annexure – E )

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

Bed sheets, pillow covers, face towels are washed every trip. Woolen blankets are dry cleaned once in two months basis and date of washing is tagged to woolen blankets.

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

At present passenger feedback forms are collected by BEDROLL attendants and the same are analyzed and corrective action and prevention action is taken. ( Annexure F )

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

Being followed

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

The existing contract is up to 22.7.2012 and the fresh contract is under finalization. Rodent control of coaching yard is awarded separately by the Engineering department.

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

Being followed

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

Being followed

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

Being followed ( Annexure – G )

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

Being followed

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

Being followed

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

Canon Smoke Generator is being used during IOH

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

Being followed

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

Being done

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

Being done


S.No. Item Clause Observations xi. Broad methodology for measuring the level of

infestation of cockroaches and rodents and expected reduction over time is in place

Level of efficiency of pest management is guided by number of public complaints and retreatment is done based on complaints if any

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

Passenger complaints on Pest control are analysed and corrective action is already taken.

25. Passenger amenities provided in various

types of coaches as specified

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

All are provided as per standard list for various types of coaches.

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

At present only four pit lines are having 24 coaches capacity. Out of 6 pit lines one is with CAMTECH design with catwalk, 5 pit line with conventional with catwalk.

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

Para 1009 of Chg manual

27.1 Wheel and axle Para 1009 a of Chg manual

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

All the wheels are checked with tyre defect gauge during PM and schedule attention. Adequate number of calibrated gauges available at this depot.

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)

Being followed

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

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

Being followed

a) Shattered Rim

b) Spread Rim

c) Shelled Tread

d) Thermal Cracks

e) Heat checks

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

Being Followed

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

Being followed

27.2 Roller Bearing Axle Boxes Para 1009 b of Chg manual


S.No. Item Clause Observations 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.

Being followed (Annexure- I )

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

Being followed.

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.

Being followed. The list of the cases is enclosed (Annexure- J )

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

Being followed

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

Being followed

ii) If temperature is found above 800 C, the

affected coach will be detached. Being followed

27.4 Minimum permissible wheel diameter in ICF design BG coaches.

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

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

Being ensured

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

Being followed

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

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

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

All the brake blocks are procured as per standard specification.

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

All the guidelines are being followed.

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

Being followed

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

RDSO spec and STR Being followed

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:

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

All the items are providing by shops during POH and the depot


S.No. Item Clause Observations Snack table in each bay. Mirrors in each bay Magazine holders on partition wall Bottle and tumbler holder

is ensuring during maintenance.

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

Followed as per guidelines

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.



iii) Short distance Duronto with 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.


NA

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.


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.

Enclosed in Annexure-K

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

Enclosed in Annexure-L

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.

Enclosed in Annexure-M

29.8 Facilities for pit line and sick line attention CAMTECH Maintenance

Manual for BG Coaches of

ICF design,

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

Enclosed in Annexure-N


S.No. Item Clause Observations observed. 1

st correction slip–

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

30 Passenger satisfaction

30.1 OBHS & escorting of trains

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

This depot is provided OBHS for only six trains as per Railway Board guide lines (12704/12703, 17016/17015, 17018/17017, 17037/17038, 12791/12792, 12285/12286)

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

In 12220 SC – LTT Duronto Exp. Cleaning staff is deputed along with escorting staff.

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

6 Trains (12704/12703, 17016/17015, 17018/17017, 17037/17038, 12791/12792, 12285/12286)

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

Nil

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

Average PSI is 93%. Yes system exists for verification

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

Yes, passenger feedback is being collected by the Bedroll attendants for linen and pest management. Passenger feedback is collected by OBHS staff for cleanliness and condition of the coach and proper corrective action being taken.

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.

Being followed

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.

This activity is out sourced to the outside agency for all PM & SM rakes and list of equipment and nos of rakes is enclosed as Annexure-N

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

Depot has facility and being used.

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

Yes, Ensuring washing of curtains once in every 15 days as per RB guidelines.

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

Woolen blankets are dry cleaned once in two months basis and date of washing is tagged to woolen blankets.

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.

Being ensured


S.No. Item Clause Observations b) Action in respect of implementation of systems

of system for collection bagging and disposal of leftover food from pantry cars and coaches.

The leftover food garbage are collected from the coach and dumped at the nominated locations and further disposal by Municipal Authorities

c) Sustainable garbage collection and disposal system

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

Water drainage system is good and observed no blockage of drains

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

Periodic fumigation of coaches and high standards of cleanliness in washing lines is being ensured on PM trains.

f) Monitoring the functioning of OBHS and CTS scheme.

Checks are conducted regularly for effective functioning of the 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.

At the Zonal / Divisional level, SAG / Selection grade officers by name and designation are nominated with different important Mail/Express trains under “Own your train scheme (OYTS)”. In addition to that, all the trains are also nominated to Sr. supervisors under OYT to improve the cleaning

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.

Being ensured

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

1 Ton Mechanised Laundry was commissioned on 24.12 2010.

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

The storage space for stocking linen is inadequate and additional storage space required at PF 1

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

Followed.

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

Alsthom manual and OEM manuals

Followed as per manual


S.No. Item Clause Observations Disc brake attention CDTS (Controlled discharge toilet

system)

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

Followed as per manual. List Of defects enclosed.(ANNEXURE – O)

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

Followed as per 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

Followed as per the Rly.Board Letter No. 83/M (N)/960/1/Vol I dated 15/18.3.99).

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

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

Yes available.

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

Ensured.

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.

4 No.s of wheel sets are available.

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

4 No.s of wheel sets are available.

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

LHB coaches are due for shop schedule from this month and followed.

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

During primary maintenance every box is checked for symptoms of grease oozing out.

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

During primary maintenance Drain holes are cleared in the control arm

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

Ensured

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.

Torque wrenches with suitable torques are being used for


S.No. Item Clause Observations 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.

tightening the Phonic wheel screws.

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.

The clearance between the phonic wheel and speed sensor is checked during – D2 Schedule

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.

Procurement is under process.

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

During every trip, the cables are checked for any loose connection and if found any are attended.

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

OEM guidelines Dump valve connections are checked and if any leakage through dump valve is found, the valves are replaced under warranty. So far two dump valves are replaced.

31.6 Earthing Device OEM guidelines Check for quantum of defective devices

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

List of Survey conducted for proper functioning of Earthing devices is enclosed.(ANNEXURE – P)

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

Junction box in broken/damaged condition. 2 Broken junction boxes are replaced.

31.7 Disc brake attention: OEM guidelines

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

40 No.s of brake pads are available. Procurement of Brake pads is under process.

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

During primary maintenance the brake calliper is checked for any damages/cracks.

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

Followed

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

Followed

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

Followed as per the guidelines.


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 Remarks

Minor Depot Below 100

Medium Depot 100 to 250

Major Depot Above 250 720(SC depot)

Machinery and Plant

Description Minor

Depot

Medium

Depot

Major

Depot

Observation

U/floor wheel lath - - 1 1

Whiting jacks (5 Nos.) - 1 set 1 set 9 Nos.

EOT crane 20T - - 1 NA

Coach Shunter - 1 2 NA

Welding Plant 1 2 4 9Nos

Gas Cutting Equipment 1 2 2 12Nos

Vacuum Exhauster 1 2 2 NA

Air Compressor 30 cfm 1 2 2 5Nos

Portable Vacuum Testing Equipment - 1 1 NA

Portable Air Compressor - - 1 1

2T Tram beam hoist 1 1 2 3Nos (7.5T)

Sewing machine - 1 1 NA

Truck 10T - - 1 3 Nos

Light Coml. Vehicle 1 1 1 1 No

Fork lift truck - - 1 2 Nos

Lister truck 1 1 2 2 Nos

Car Washer - 1 1 6 Nos

Portable Trolley Light 2 4 NA

Cotton waste soaking plant 1 1 1 NA

Wood cutting saw machine - 1 1 NA

Hand shearing machine - 1 1 NA

Portable Furnace 1 1 2 NA

Centre Lath - - 1 NA

Bogie Manipulator - - 1 1 No

Ultrasonic Testing Apparatus 1 1 1 NA

Tool post Grinder - 1 1 4 NOS.

Vacuum Cleaner 1 2 3 2 NOS.

Pressure Jet Cleaner 1 2 4 5 NOS.


Tools

a. Pneumatic Hand Tools

i. Grinder 1 1 2 1 NO.

ii. Drill 1 1 2 NA

iii. Chipper / Buster - 1 2 NA

iv. Riveter - - 1 NA

b. Electric Power Tools

i. Pop Riveting Gun - 1 1 1 NO.

ii. Drill - 1 1 1 NO.

iii. Bolt Tightner - - 1 NA

c. Hand Tools As required AVAILABLE

d. Test Bench

i. Water Tank Test Rig - 1 1 NA

ii. D.A. Valve Test Bench - 1 1 NA

iii. Vac. Cyl. Test Bench - 1 1 NA

iv. Slack Adjuster Test Bench - 1 1 NA

v. DV Test Bench - 1 1 NA

vi. Air brake single coach test rig - 1 1 2 Nos

e. Office Equipment

i. Computer system 1 1 1 6 Nos

ii. Plain Paper Copier 1 1 2 1 No

iii. Telefax 1 1 1 No


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 (BP+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: SC coaching depot and SC

1. Coach Holding

Mail/Expresses coaches with conventional coupling 655

Mail/Expresses coaches with CBC coupling -

Rajdhani/Shatabdi coaches (conv) -

LHB coaches (Rajdhani/Duronto) 24( Hybrid ) + 22( Fiat )

Shatabdi Coaches (conv)

Shatabdi coaches (LHB)

Passenger coaches -

OCV’s 39

Grand Total 740

2. Maintenance attention of at depot

PM of Mail/Expresses train with secondary attention at other end 5 trains & 89 coaches

PM of Mail/Expresses train with round trip attention at other end 12 Trains & 233 Coaches

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

Total PM attention at depot: 17 trains & 224 Coaches per

day

Total SM attention at depot: 3 Trains and 9 coaches per

day

Total Round trip attention at depot: 22 Trains & 323 Coaches

per day

3. Pit line attention

24 coach pit with catwalk and high pressure water jet

facility/watering facility at per CAMTECH’s guidelines

1. One pit line (L2) as

per CAMTECH

guidelines.

2. Three pit lines(L3,

L4, L5) with 24

coach length

24 coach pit facility without catwalk

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

be collected)

2 Pit lines in washing siding

with cat walk

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

1

1

2

Compressed air with reservoir and ir dryer/moisture trap facility

with test rig (RTR)

5

Facility for welding at Yard attention Available

Night maintenance facility with overhead/pit light as per

CAMTECH’s guidelines

Only two pit lines(L2 & L3

are having pit lighting facility)


4. Sick line facility

Coach lifting facility with overhead crane Not available

Coach lifting facility with JMP jack/hydraulic jack 8 Synchronised jacks are

available

Total coach accommodation

With pit attention Without pit attention

2

2

Facility for compressed air with test rig (SCTR) Available

Availability of hydrant water for overhead tank attention 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.

All the lines on platform are having Rolling –in Lights

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

As per yardstick staff strength is inadequate.

7. Training status of supervisor and staff – It is being ensured that no supervisor and staff are

overdue for training.

8. Availability of critical/ safety stores and storage system. Critical/safety items are available and the

system of storing the materials is good.

9. Availability of coaches as per rake link with maintenance spare. Maintenance spares are not

available.

10. Bottlenecks / limitations of system / depot.

a. Supervisors position is very acute with so many activities like linen management,

Breakdown, ,Mechanised Laundry, Various contracts Management. Etc.

b. In washing siding Rakes having more than 18 coaches load are maintained in two

hooks. To overcome this work has been sanctioned for extension of the pit line.

11. Safety performance record. Good

12. Performance of critical spare Good


ANNEXURES

ANNEXURE -A

TRAINS MAINTAINED AT SC DEPOT (PRIMARY)

S. No

Train No

Name No of

Coaches

No of Rake

s

Total No of

Coaches

From To Maint. Days

Maint.Timings

From To

1 12706 Inter City Express

18 2 36 SC GNT Daily 22:00 04:00

2 17035 Telangana Express

22 1 22 SC SKZR Daily 22:00 04:00

3 12791 Patna

Express 18 4 72 SC PATNA Daily 23:00 05:00

4 12285 Duronto Express

15 1 15 SC HNZM Wed 09:00 15:00

SAT 15:00 21:00

5 17018 Rajkot

Express 21 2 42 SC RJT

SAT, MON, TUE

22:00 06:00

6 17002 Manmad Express

16 1 16 SC MMR SUN 09:00 15:00

17002

Manmad Express

20 0 SC MMR FRI 09:00 15:00

7 17016 Vishaka Express

19 3 57 SC BBS Daily 09:00 15:00

8 17064 Ajanta

Express 21 2 42 SC MMR Daily 11:00 17:00

9 12764 Padmavathi

Express 19 2 38 SC TPTY

SUN,TUE,THU,FRI,SAT

09:00 15:00

10 12732 Thirupati Express

19 1 19 SC TPTY MON,WE

D 09:00 15:00

11 12735 Garib Rath

Express 16 1 16 SC YPR

TUE,THU,SUN

10:00 16:00

12 12740 Garib Rath

Express 16 2 32 SC VSKP Daily 10:00 16:00

13 12710 Simhapuri Express

21 4 84 SC GDR Daily 15:00 21:00

14 17050 Machlipatnam

Express 24 2 48 SC MTM Daily 08:00 14:00

15 17037 Bikaner Express

21 2 42 SC BKN TUE, WED

16:00 22:00

16 12752 Manuguru Express

18 1 18 SC MUGR MON,WE

D,FRI 16:00 22:00

17 12220 Duronto Express

14 1 14 SC LTT TUE, FRI 09:00 15:00


ANNEXURE – B

TURNROUND TRAINS

TURNROUND TRAINS MAINTAINED PER DAY AT SC

SN Train New Train

No. From To

Halt

No

of C

oach

es

AT

TE

ND

ED

AT

PM

Dep

ot

DA

Y Arr. Dep

Dura-

tion

1 DHMU 22.00 4.50 6.50 12 PF Daily

2 319/305 57619/5760

5 RAL SC VKB 5.05 8.10 3.05 18 PF KCG Daily

3 2805/2806 12805/1280

6 VSKP SC VSKP 18.25 7.10

11.05

23 WS

VSKP

Daily

4 2705/7607 12705/1760

7 GNT SC KRNT 21.50 7.30 9.40 18 PF SC Daily

5 326/351 57626/5765

1 MUGR SC RAL 9.25

10.50

1.25 18 PF KCG Daily

6 2747/2748 12747/1274

8 GNT VKB GNT

10.35 /

15.05

10.45 /

15.15

0.10 17 * GNT Daily

7 406/SM-3 57306/5730

7 GNT SC MED 10.30

11.35

1.05 14 PF GNT Daily

8 7234/7202 17234/1720

2 BPQ SC GNT 10.45

13.05


9 2709/7058 12709/1705

8 GDR SC CSTM 7.45

13.30

5.45 21 WS

SC Daily

10 7201/7233 17201/1723

3 GNT SC BPQ 13.45

15.25


11 2733/2704 12733/1270

4 TPTY SC HWH 6.25

16.00

9.35 24 LY TPT

Y Daily

12 2713/2714 12713/1271

4 BZA SC BZA 11.45

16.15

4.30 20 PF BZA Daily

13 526/573 57426/5747

3 GTL SC BDHN 14.40

17.00

2.20 10 PF GTL Daily

TRAINS MAINTAINED AT SC DEPOT (SECONDARY)

S. No

Train No

Name No of

Coaches

No of Rake

s

Total No of

Coaches

From To Maint. Days

Maint.Timings

From To

1 12590 Gorakhpur

Express 23 1 23 SC GKP FRI 22:00 04:00

2 12513 Guwahati Express

18 1 18 SC GWH SUN 22:00 04:00

3 12437 Rajadhani Express

18 1 18 SC NZM WED 22:00 04:00


14 2703/2734 12703/1273

4 HWH SC TPTY 9.35

18.05

8.30 24 PF TPT

Y Daily

15 352/325 57652/5762

5 RAL SC

MUGR

17.10 18.4

0 1.30 18 PF KCG Daily

16 2737/2738 12737/1273

8 COA SC COA 6.35

21.15

14.40

24 PF COA Daily

17 0996/0995 09736/0973

5 JP SC JP 2.30

22.40

20.10

20 PF JP MON

18 12025/120

26 12025/1202

6 PA SC PA 14.10

14.40

0.30 10 PF PA

SUN,MON,WED,THU,FRI,SAT

19 22849/228

50 22849/2285

0 SHM SC SHM 15.00 5.30

14.30

14 PF SHM SUN

20 07608/076

07 07607/0760

8 MCI SC MCI 14.30 5.30

15.00

12 PF KCG

SUN, MON,TUE, WED,THU,FRI

21 09221/092

22 09221/0922

2 PBR SC PBR 9.30

14.50

5.20 16 PF PBR Wed

TOTAL 369

ANNEXURE – C

PASSTHROUGH TRAINS

PASS THROUGH TRAINS MAINTAINED AT SC

S. No

Train No

From To

Halt No of

Coaches Day of Service

PM Depo

t From To Dura-tion

1 17406 ADB TPTY 5.45 6.05 20" 19 Daily TPTY

2 11019 CSTM BBS 7.50 8.00 10" 22 Daily CST

M

3 11020 BBS CSTM 11.35 11.45 10" 22 Daily CST

M

4 12747 GNT VKB 10.35 10.45 10" 18 Daily GNT

5 12748 VKB GNT 15.05 15.15 10" 18 Daily GNT

6 17405 TPTY ADB 20.40 21.10 30" 19 Daily TPTY

1 12592 SBC GKP 7.00 7.20 20" 23 Tue GKP

2 12429 SBC NZM 7.35 7.50 15" 18 Mon, Tue, Thu, Fri NZM

3 18309 SBP NZB 8.20 8.40 20" 18 Tue, Sat SBP

4 18509 VSKP NZB 8.20 8.40 20" 18 Thu, Sun VSKP

5 11405 MMR CCT 9.20 9.30 10" 18 Mon, Fri MMR

6 17205 MMR CCT 9.20 9.30 10'' 17 Wed COA

7 17207 MMR BZA 9.20 9.30 10'' 15 Thu BZA

8 12708 HNZM TPTY 9.15 9.30 15" 18 Mon, Thu, Sat TPTY

9 17203 BVC CCT 10.30 10.40 10" 18 Sun COA

10 17204 CCT BVC 14.30 14.50 20" 18 Thu COA

11 12591 GKP SBC 15.10 15.30 20" 23 Sun GKP


12 17206 CCT MMR 16.25 16.50 25'' 17 Mon COA

13 17208 BZA MMR 16.25 16.50 25'' 15 Tue BZA

14 11406 CCT MMR 16.25 16.50 25" 18 Wed, Sat MMR

15 12707 TPTY HNZM 17.25 17.55 30" 18 Mon, Wed, Fri TPTY

16 15015 GKP YPR 17.50 18.20 30" 22 Tue GKP

17 12430 NZM SBC 18.35 18.50 15" 18 Tue, Wed, Sat, Sun NZM

18 18310 NZB SBP 21.10 21.30 20" 18 Tue, Sat SBP

19 18510 NZB VSKP 21.10 21.30 20" 18 Thu, Sun VSKP

20 15016 YPR GKP 23.10 23.30 20'' 22 Thu GKP

21 12493 SBC NZM 7.35 7.50 15" 18 Wed, Sat, Sun NZM

22 12494 NZM SBC 18.35 18.50 15" 18 Thu, Fri, Mon NZM

23 12750 LTT VSKP 2.00 2.10 10" 15 Fri, Mon VSKP

24 12749 VSKP LTT 21.00 21.10 10" 15 Wed, Sat VSKP

25 12581 PA BBS 21.30 21.40 10" 15 Thu PA

26 12582 BBS PA 17.40 17.50 10" 15 Wed PA

27 12213 YPR DEE 9.00 9.15 15" 15 Sat DEE

28 12214 DEE YPR 21.25 21.40 15" 15 Thu DEE

29 17213 NS NSL 20.10 20.35 25" 16 Tue, Fri) NS

30 17214 NSL NS 23.20 23.40 20" 16 (Wed, Sat) NS

ANNEXURE –D

TURNROUND TRAINS MAINTAINED PER DAY AT SC

S.No

Train New Train

No. From To

Halt

No

of C

oach

es

AT

TE

ND

ED

AT

PM

Dep

ot

DA

Y Arr. Dep

Dura-tion

1 DHMU 22.0

0 4.50 6.50 12 PF

Daily

2 319/305 57619/5760

5 RAL SC VKB 5.05 8.10 3.05 18 PF KCG

Daily

3 2805/2806 12805/1280

6 VSKP SC VSKP

18.25

7.10 11.05 23 WS VSK

P Dail

y

4 2705/7607 12705/1760

7 GNT SC KRNT

21.50

7.30 9.40 18 PF SC Dail

y

5 326/351 57626/5765

1 MUG

R SC RAL 9.25

10.50

1.25 18 PF KCG Dail

y

6 2747/2748 12747/1274

8 GNT

VKB

GNT

10.35 /

15.05

10.45 /

15.15

0.10 17 VKB

GNT Dail

y

7 406/SM-3 57306/5730

7 GNT SC MED

10.30

11.35

1.05 14 PF GNT Dail

y

8 7234/7202 17234/1720

2 BPQ SC GNT

10.45

13.05

2.20 18 PF GNT Dail

y

9 2709/7058 12709/1705

8 GDR SC CSTM 7.45

13.30

5.45 21 WS SC Dail

y

10 7201/7233 17201/1723

3 GNT SC BPQ

13.45

15.25

1.40 18 PF GNT Dail

y

11 2733/2704 12733/1270

4 TPTY SC HWH 6.25

16.00

9.35 24 LY TPT

Y Dail

y

12 2713/2714 12713/1271 BZA SC BZA 11.4 16.1 4.30 20 PF BZA Dail


4 5 5 y

13 526/573 57426/5747

3 GTL SC BDHN

14.40

17.00

2.20 10 PF GTL Dail

y

14 2703/2734 12703/1273

4 HWH SC TPTY 9.35

18.05

8.30 24 PF TPT

Y Dail

y

15 352/325 57652/5762

5 RAL SC

MUGR

17.10

18.40

1.30 18 PF KCG Dail

y

16 2737/2738 12737/1273

8 COA SC COA 6.35

21.15

14.40 24 PF COA Dail

y

17 0996/0995 09736/0973

5 JP SC JP 2.30

22.40

20.10 20 PF JP MON

18 12025/1202

6 12025/1202

6 PA SC PA

14.10

14.40

0.30 10 PF PA

SUN,MON,WED,THU,FRI,SAT

19 22849/2285

0 22849/2285

0 SHM SC SHM

15.00

5.30 14.30 14 PF SHM SUN

20 07608/0760

7 07607/0760

8 MCI SC MCI

14.30

5.30 15.00 12 PF KCG

SUN, MON,TUE, WED,THU,FRI

21 09221/0922

2 09221/0922

2 PBR SC PBR 9.30

14.50

5.20 16 PF PBR Wed

TOTAL 369

ANNEXURE –E

LINEN CONDEMED AT COACHING DEPOT SC

LINEN CONDEMNED AT SC DEPOT

White bedsheets 44,330


White pillow covers 41,269

White face towels 22,239

White bath towels 82

P.V.Bedsheets 329

P.V.Pillow covers 319

Woollen blankets 1,455

Foam pillows II A.C 1,947

Foam Pillows I A.C 6

Canvas bags 78

ANNEXURE - F

LINEN FEEDBACK FROM APR’2011 TO MAR’2012

Firm name No.of

Trains

Total Feed

back

collected

Bad Satisfactory Good Excellent

White choice 18 577 49 260 251 17

Novex 31 4817 627 2166 1859 165

Supreme

Laundromat

53 7593 122 4148 3940 204

Garments 75 8293 128 4008 3863 296

Mech.Laundry 40 12502 25 4548 5738 2091

Sparkles 30 6785 18 3310 2993 464


ANNEXURE – G

v Toilet Kit for 2 Persons

1 Kit Box 1No.

2 Mugs 2Nos.

3 Steel wool 2pieces

4 6No. Brush 2Nos.

5 Nylon Round Brush 1No.

6 Scraper Patti 1No.

7 Sponge 2Nos.

8 Bucket 3Nos.

9 Scrotch Pad 2Nos.

10 Broom goa 2Nos.

11 Nylon Hockey Toilet Brush 1No.

12 Special Cotton duster clothe(48cm x 48cm) 1No.

13 Jute cotton duster clothe (45cm x45cm) 1No.

v Interior Cleaning Kit

1 Kit Box 1No.

2 Bucket 2Nos.

3 Sponge 1No.

4 Scraper Patti 1No.

5 Special Cotton duster clothe(48cm x 48cm) 1No.

6 Jute cotton duster clothe (45cm x45cm) 1No.

7 Spray Bottle (Glass cleaner) 1No.

8 Window glass Sqeeze (Handle preferably 10 inches length, Blade of 45 cm) 1No.

9 Mug 1No.

10 Scrotch Pad 1No.

11 Broom goa 1No.

12

Disposable Bag for garbage (Milky white coloured polyethylene of a size 20" X 30" and 80 micron guage. Bag shall be printed with "Clean Rake Station" Name of the Contractor and Name of the Cleaning Station.

1No.

13 Floor mop (Approx. 24 inches width and Handle shall be at least 1 meter & made of mild steel or aluminum)

1No.

v Exterior Cleaning

1 Washing No.12 Brushes 2Nos.

2 Scrotch Pad 1No.

3 Buckets 2Nos.

4 No.6 Brush 1No.

5 Sponge 2Nos.


ANNEXURE -G

Chemicals using in Mechanized Coach Cleaning - Sc depot

Name of the Chemical Make Usage area Dilution Ratio with

water

TASKI R1 Johnson Diversey Bathroom cleaner 1:20min - 1:50max

TASKI R6 Johnson Diversey Western type toilet bowl cleaner

Ready to use

TASKI D7 Johnson Diversey Steel & Alluminium wash basins Polisher

Ready to use

TASKI R5 Johnson Diversey Air - Freshener Ready to use

TASKI R3 Johnson Diversey Glass cleaner 1:20min - 1:50max

TASKI SPIRAL (F11Y) Johnson Diversey Floor Cleaner 1:20min - 1:50max

TASKI R7 Johnson Diversey Interior of the coach 1:20min - 1:50max

RAIL CLEAN TYPE-II Johnson Diversey Exterior of the coach 1:20

SCENTED PHENYL

All the primary and secondary trains are covered under MCC.

Periodicity of IOH attention:

S. No Year No. of IOH attended

1 2009-10 420

2 2010-11 422

3 2011-12 557

Annexure - H

S. No Description Year

2009-10 2010-11 2011-12

1 Axle box canted 0 0 2

2 Axle box wing crack 4 1 3

3 Deep & Hollow tyre 35 46 21

4 Less root at radius 2 4 1

5 Sharp flange 4 22 9

6 Shelled tread 19 29 25

7 Skidded wheel 2 3 21

8 Other wheel defect 6 15 11


Annexure – I

S. No Description Year

2009-10 2010-11 2011-12

1 Hot axle 0 1 1(SM)

2 Damaged axle box 0 0 0

3 Damaged front or rear cover 10 12 5

4 Seized roller bearing 0 0 0

5 Coach involved in accident, derailment, fire, flood etc

0 0 1

6 Grease Oozing 1 2 2

-

J SICKANALYSIS

ANNEXURE -J

S.No Defects 2009-

10 Monthly Average

2010-11 Monthly Average

2011-12 Monthly Average

1 Wheel defects 73 6.08 122 10.17 93 7.75

2 Bogie defects 103 8.58 155 12.92 90 7.5

3 Brake gear defects 35 2.92 58 4.83 41 3.42

4 Interior repairs/Ext painting 39 3.25 34 2.83 28 2.33

5 Water tank repairs 42 3.5 33 2.75 46 3.83

6 Buffing gear 20 1.67 21 1.75 29 2.42

7 Door repairs 16 1.33 3 0.25 17 1.42

8 Foot board /Body Repairs 10 0.83 3 0.25 7 0.58

9 Pipe line defects 15 1.25 11 0.92 26 2.17

10 Draw gear repairs 2 0.17 2 0.17 4 0.33

TOTAL 355 29.58 442 36.84 381 31.75

Primary detachments: (Annexure-K) -NIL- Secondary detachments: (Annexure-L) -NIL- Enroute detachments: (Annexure-M) -NIL-


FACILITIES AVAILABLE AT COACHING DEPOT SC

ANNEXURE - N

INFRASTRUCTURE PITLINES

Siding point Pit line No. Length in

meters Capacity in

coaches Catwalks

No. of Hydrants

Remarks

W/Siding 1 400 17 Available 43 High pressure jet

available

W/Siding 2 360 16 -do- 42 -do-

Lower yard 2 610 26 -do- 50 High pressure jet not available,pit lihting available

Lower yard 3 607 26 -do-

47

High pressure jet available,pit

lighting available

Lower yard 4 552 24 -do- High pressure jet

available

Lower yard 5 534 24 -do- 44 -do-

PLATFORMS

Platform No. Length in

meters

Capacity in

coaches

No. of Hydrants

High Pressure pipeline

1 615 24 189

2 630 24

3 630 21 162

Available

4 515 21 Available

5 515 23 262

6 600 24

7 600 24 No provision

8 580 24 178

9 580 24 175

10 580 24 Available

SICK LINE/IOH SHED

Line

Covered area Uncovered area

Length Working capacity

Pit Length Capacity

8 35 M 1 Coach - 35 M 2 Coaches

9 35 M 1 Coach Yes 35 M 2 Coaches

10 35 M 1 Coach Yes 35 M 2 Coaches

Wheel defects in LHB coaches


ANNEXURE – O

Sl.No. Defect No.of cases

1. Wheel skidding 1

2. Wheel Shelling 10

31.6 Earthing equipment Failure

ANNEXURE - P

Defect Make No.of coaches

Damaged Carbon brushes, clip

assembly and brush wires

Darshan Enterprises 3

Damaged clip assembly and one

string of brush wires cut.

Darshan Enterprises 3

Clip assembly damaged Darshan Enterprises 2

String of brush wires cut Darshan Enterprises(3)

CCERS (1)

4

Documents

Quality Audit report Of Coaching Depot Secunderabad, SC ...rdso.indianrailways.gov.in/works/uploads/File... · on divisions where rake has been based for primary maintenance. 112(a)