Work Profile in C & W Work Profile in C & W Depots of Indian Depots of Indian

RailwaysRailways

Presented by

M.T.Sujith Kumar SE / C&W / BBQ

ENGINEERS & STAFF OF ENGINEERS & STAFF OF OPEN LINEOPEN LINE

SENIOR SECTION ENGINEER

JUNIOR ENGINEER

ARTIZANS (THREE GRADES)

Work AreasWork AreasAs In-charge of Depot, IOH/ROH Sheds, Sick line, M & P, Stores, Break Down, MIS and Rake Maintenance activities in C & W Depots.As C&W, M&P and Safety Inspectors in Divisional and Zonal Headquarters.As Instructors & Lecturers at STCs and BTCs.As C&W Controllers in Divisional and Zonal control offices.

DUTIES , RESPONSIBILITIES & REQUIREMENTS

OF

OPEN LINE ENGINEERS

ADMINISTRATIVE DUTIESADMINISTRATIVE DUTIESDepot InDepot In--chargecharge

Responsible for all activities in the Depot.-Technical, Administrative, Ministerial, etc and for Effective execution of administrative policies and plans.

Maintain Out-turn targets and train schedules.Efficient Stores & Material Management.Effective Human Resource Management.Provide on the job training for trainees, apprentices & conducting trade test, suitability test etc.

ADMINISTRATIVE DUTIESADMINISTRATIVE DUTIES Cont..Cont..

Plan for capacity augmentation in Infrastructure, machinery, plant, material and manpower.Preparation of Tender & Liaison with out side agencies for Out sourcing, technical suitability, vendor rating, implementation of contractual obligation etc.Preparation of annual M&P and works programme & maintenance of M&P and related equipments.Maintenance of Industrial peace, Staff discipline, DAR proceedings etc.

ADMINISTRATIVE DUTIESADMINISTRATIVE DUTIES Cont..Cont..

Ensure safety of Men, Material and Traveling Public through intensive Supervision and Quality Control. Maintenance of Accident relief trains including Re-railing equipment, First aid equipment, spares, cranes, etc.“Effective Disaster Management”. Restoring normalcy during natural calamities and accidents.Maintain the integrity and punctuality of Train services during natural calamities like flood, storm etc.

TECHNICAL DUTIESTECHNICAL DUTIESMaintenance, Repair and Certification of the entire Rolling Stock Inventory of Indian railways comprising– 2.3lakh Wagons– 48500 Coaches for Safe, Reliable and Punctual Train

operation.Planning of maintenance activities including placement of rakes in Pit Lines, balancing of rake occupation in Pit Lines.Detachment of Coaches and Wagons for Scheduled maintenance activities like POH and IOH / ROH, etc.

Preventive Maintenance activities of Coaches and Wagons in Pit Lines and Yards. (Examination and rectification of each and every component, for any failures, abnormalities and unsafe condition, which may endanger the safety of the train.Analysis and reporting of component failures.Certification of the entire train for its overall safety till the train returns to the originating station.Maintenance of all registers with respect to train service.Issuance of Brake Power Certificate.

TECHNICAL DUTIESTECHNICAL DUTIES Cont..

TECHNICAL DUTIESTECHNICAL DUTIES Cont..

Maintenance and upkeep of Brake Down specials.Planning and execution of re-railment and restoration at accident sites.Maintenance activities in Sick lines and ROH/IOH Sheds.Upkeep of Machineries and plants.Monitoring of trial components.Prevention and analysis of enroute failures like train parting, brake binding, hot axle, etc .

Need to posses the complete technical knowledge / working knowledge of the rolling stock as a whole and all its individual components.

Need to posses the technical knowledge of all the Rolling stock manufactured in the past few decades till their complete life span

Whenever new technologies are introduced, adapt to the new technology by self-learning.

Impart training to field staff to update the latest technical developments in rolling stock.

SPECIAL REQUIREMENTS of OPEN LINE ENGINEERS

ACCOUNTABILITYACCOUNTABILITYCustodian of all assets including Machineries and Plant, Stores and other related equipments worth several crores.Planning and Running of special trainsSubject to Audit by the Divisional Audit Personnel.For any failure of the system in train service.For out turn target of wagons/coaches in sick lines and Intermediate / Routine Overhauling.For detention of trains on C&W accountFor any failure in components of the certified train.For any failure in the brake power.

MULTIFACETED SKILLS & ROLESMULTIFACETED SKILLS & ROLESAdministrative abilities to manage and run Depots.Possess up to date Technical knowledge of various types of Rolling stock and its components.Managerial Skills to manage the work force to meet the quality and safety standards.Assess the knowledge level of work force under him for proper distribution of work.Ministerial skills to ensure proper recording of the data.Technical scrutiny of tender papers for procurement of Rolling Stock components and services.

MULTIFACETED SKILLSMULTIFACETED SKILLS ( Cont..)( Cont..)

Tutor and mentor to educate the work force continuously to keep up with modernization.Complete Knowledge of DAR proceedings to tackle erring staff.Planning for improvements.Crisis management for restoration in case of accident or breakdown.Failure analysis and Investigation to find out and rectify the reasons.Maintenance of Accident relief trains including Re-railing equipment, First aid equipment, spares, cranes, etc.

Duties performed byDuties performed byOpen Line C&W Open Line C&W

Engineers during Engineers during Train maintenanceTrain maintenance

BASIN BRIDGE COACHING DEPOT

Chennai Division / S.Rlyis taken for Illustration

BBQ –The only C&W maintenance depot ISO certified for its entire operations in Indian Railways.

Coach Position of BBQCoach Position of BBQBARE REQUIREMENT - 755INEFFECTIVE - 75.48 (12% FOR AC AND 10 % FOR NON AC) ----------TOTAL (A) - 830.48TRAFFIC SPARE (B) - 94.38 (12.5%) OF A ----------TOTAL REQUIREMENT (A+B) - 925ACTUAL AVAILABLE - 807SHORTAGE * - - 118

* The shortage results in coaches being cannibalized from other incoming rakes to meet the demand depriving them of the mandatory maintenance time

Coach MaintenanceCoach Maintenance

Sick Lines / IOH ShedsBreak Down Attention & C-Schedule / IOH Attention

Yard / PlatformMaintenance of Accident Relief Trains

PlatformsOther End Attention

PlatformsPlatform Turn-around Attention

Pit Lines in YardSecondary Maintenance

Pit Lines in YardPrimary Maintenance

PlaceType

Primary MaintenancePrimary Maintenance-- Carried out for the Train as a wholeCarried out for the Train as a whole

Need - Mandatory for every train. Place - Pit Lines in Coaching yards.Works - Safety, Amenity, Electrical, A/C, Internal

& External cleaning and Brake power testing with certification.

Time - Minimum 6 Hrs in Pit lines.Day/Night - Both Day & Night.Lighting - Ambient light during day time and

primitive minor lamps during night.Validity - Up to 3500 Kms Max.

PITLINE MAINTENANCE

Inspection, testing and attention of all the vital safety components

both visually and using inspection tools and gauges to ensure safety

of the whole train.

Thorough examination and attention to the brake system to ensure 100 % brake power.

Inspection and testing of Passenger emergency alarm system.

Ensuring the availability of correct destination and coach indication boards.

Testing and attention of all Electrical fittings & equipments(, batteries, alternators, lights & fans)

PITLINE MAINTENANCECont…

Ensuring availability and working of all passenger amenity and safety fittings.Exterior and interior Cleaning of coaches using chemicals and detergents.Watering of all the coaches.Execution of all Preventive Maintenance schedules.(A & B Schedules as per IRCA part IV)

PITLINE MAINTENANCECont..

Vital Safety ComponentsVital Safety Components

Running Gear Components Suspension Gear ComponentsDraw & Buffing gear componentsBrake gear componentsUnder frame & Bogie ComponentsAir-conditioning equipmentsElectrical Equipments

Components that must be Examined Components that must be Examined During Pit ExaminationDuring Pit Examination

1012 mts46 mts (Aprox)Pipe Lines

6666303Total

2420110Under Gear

143065Brake Gear

61628Draw & Buffing Gear

176080Suspension Gear

44020Running Gear

Per rake of 22 Coaches

Major Components /Coach

2640 Sq Mtrs120 Sq MtrsExterior cleaned

22010Doors & Fasteners (Main / Toilet) &

Vestibules

158472Window shutters & Fastenings

35200 ltrs1600 ltrsWater to be filled

30814Flush/Push cocks, Taps & Valves

Rake of 22 CoachesPer Coach

Other Components & ActivitiesOther Components & Activities

This apart the availability and correctness of more than

145 Cotters & Split pins &

150 Bolts and nutsin every coach need to be

physically ensured

PLATFORM MAINTENANCERECEPTION

ROLLING IN EXAMINATION(Visual inspection of dangling parts, hearing for any unusual sound)

AXLE BOX FEELING(Sensing the temperature of axle boxes by thermo hunters / hand by kneeling down in the gap between platforms and coach)

RELEASING OF BRAKES(Manually pulling of DV release valve by kneeling down in the gap between platforms and coach)

DESPATCH

PLATFORM MAINTENANCE(Examination,cleaning ,watering and certification of platform turnaround trains and pass through trains ensuring safety)

CONTINUITY CHECK (Connecting all the air hoses of coaches and ensuring the continuity of air pressure through the formation)

ROLLING OUT EXAMINATION (Visual inspection of dangling parts, hearing for any unusual sound)

PLATFORM MAINTENANCE Cont..

SICK LINE MAINTENANCE

Execution of preventive Maintenance Schedules IOH & C- Schedule as per IRCA Part IV.

Carrying out break-down maintenance.(To maintain the prescribed ineffective percentage of 2.5% of total coach holding)

Any other special works nominated by authorities.

To be alert on duty round the clock and responding to the accident / derailment with in 20 min.

Arranging protection to passengers and their belongings.

Render first aid and arrange for medical assistance.Restoration of track and traffic (re - railing) within

the shortest possible time.Investigation of causes and recommendation for

preventive action.Reclamation of assets.

ACCIDENT RELIEF TRAINS

OTHER ACTIVITIES

Assessment , Procurement and Maintenance of Machinery and Plants & Tools and Plants.

Maintenance of saloons and inspection vehicles.Planning ,Procurement ,stocking and issue of items

required for day to day maintenance activities.Planning and processing of Outsourcing activities/

services.Maintenance of Management Information

Systems(MIS).Processing and maintaining ISO certification ,etc.

Defects detected during the last 5 years at

BBQ / SR

Defects affecting Train safetyDefects affecting Train safety

222245360445473Under Gear

138181129179218Draw & Buffing Gear

464492527634632Brake Gear

278325445378461Suspension

5105466531142861Running Gear

20072006200520042003Nature of Defects

Interior DefectsInterior Defects

9511180113713121355Total

6087117166188Body Panel & Carpentry

167257228214203Berth & Window Shutters

275301332507505Main Door, Lav. Door, Passage

Door & Vestibules

449535460425459Plumbing & Water tank repairs

20072006200520042003

DASH POT SPRING BROKEN

AXLE BOX COVER PUNCTURED

BOGIE FRAME CRACK

BRAKE HANGER PIN MISSING

BSS HANGER MISSING

BUFFER PLUNGER BROKEN

SIDE BEARER PILLAR CRACKED

PITTED WHEEL

SHELLED TREAD

WORK ENVIRONMENTOpen- to - sky environment facing hot sun , heavy rain,

storms, cold weather etc.,

Physical handling and working with coach components splashed with human excreta and other animal wastes.

Haphazardly and unscientifically constructed Pit lines without sufficient working space and facilities

Exposure / Contact with chemicals and other hazardous compounds used for cleaning due to parallel execution of various maintenance activities (Electrical, Under gear Maintenance, Interior & Exterior cleaning and Air-conditioning maintenance)

Sewage water stagnation due to improper / defective drainage facilities.

Insufficient lighting with only the primitive Miner Lamps to carry out the maintenance during Night.

Flooded Pit lines during monsoon.Mosquito , Snake , Rat , Cattle and Stray dog Menace. Continuous exposure to 110V DC Power system which is

detrimental to health.Exposure to Sulphuric acid in batteries.

WORK ENVIRONMENT Cont..

WORK ENVIRONMENT Cont..

The staff engaged in inspection of rake/train has to walk a minimum of 1.5 Kms around the rake and has to inspect around 6000 components of safety category with in short span of time by exerting himself by kneeling and standing several times.

ConstraintsConstraintsInsufficient Pit Maintenance Time

(Due to late running, Interconnection of trains, Bunching of Trains in both Departure and Arrival, Shunting movements, Cross movements,etc.)

Haphazardly and Unscientifically constructed Pit lines without sufficient working space and facilities

(Out of the 19 pit lines at BBQ only 2 conform to CAMTECH norms)

Absence of proper Pit lighting & Yard lighting for Night examination.

(Night Examination carried out with only primitive Miner lamps)

Constraints Constraints Cont..Cont..

Lack of allocated spare coaches(Resort to cannibalization of coaches from other

rakes to replace sick coaches)Indiscriminate running of Special Trains without sufficient Coaches.

(Resulting in reduced maintenance time for coaches)Shortage of Staff

SPECIAL TRAINS

These are trains operated throughout the year in addition to

the regular trains for various reasons

Special Trains are operated for various reasons.

To Clear Wait Listed PassengersFor Summer/ Winter VacationsDuring Festival / Pooja SeasonDuring Sabarimala pilgrimage SeasonFor Organized Tour Package Special Trains / Coaches.VIP MovementsInspectionsHanding over of Other Division/Zonal CoachesTrains of Sister Depots for want of Pit lines / FacilitiesDedicated VP Specials ( Parcel Vans)

SPECIAL TRAINS Cont..

The coaches for the Special trains are brought from the Traffic spare coaches pooled in Railway Zonal Level which are over and above the holding of the Depot as per the requirement of that Region/Depot.

Demand of Special Trains/Coaches will vary from Region to Region as per the season.

No additional remuneration or Incentive for Running Specials and Extra Coaches is provided to motivate for the extra work load of the special trains which is over and above stipulated work load and norms.

52783064351254TOTAL00393MAR

27315554FEB9555457834JAN8545054432DEC816451448NOV

352434553026016OCT152252521423914SEP152252321618812AUG24012213121087JUL540274542648027JUN880405403289850MAY404212341381847APR

CoachesServicesCoachesServices CoachesServicesMonth 2008 – 2009 2007 – 20082006 – 2007

Special Trains Maintained at BBQ

IN SPITE OF ALL THESE PROBLEMS THE TRAINS ARE EXAMINED AND

CERTIFIED IN TIME ONLY BECAUSE OF THE COMMITMENT &

SINCERITY OF THE TECHNICAL STAFF

Impact of Technical Impact of Technical Advancement & Advancement & ModernizationModernization

Unlike other areas, the benefits of Technical advancements viz- Improved component reliability and modern materials has not reduced the workload of technical staff.- The number of components to be examined

and certified during each maintenance has increased over the years.

- The responsibility of any failure still rests with the Engineer last certified the train.

ImpactImpact Cont..Cont..

The advent of modern materials and technology resulted in manifestation of new type of defects and problems.- Introduction of Composite Brake Blocks resulted in

7 new type of wheel failures.The benefits of technical advancements are offset by increased Kms and Load.- Validity of certification increased to3500 Kms for

Coaching and 7500 Kms for Wagons. - Train composition increased to 60 wagons and 25

Coaches.- Gross load of wagons increased up to 90 tons

ImpactImpact Cont..Cont..

ImpactImpact Cont..Cont..

The modern components with advanced pneumatics and electronic controls demands more discretion and diversified knowledge to maintain and repair. Eg.- CD Toilet System

Wheel Slide protectorsPneumatic suspension Disc BrakesCoaching CBC , etc

ImpactImpact Cont..Cont..

Types of Wagons and Coaches increased over the years.No major change in Infrastructure and other facilities.New technology, materials and system poses newer problems which need to be addressed during maintenance without any prior training or guidance.

Technical v/s Commercial & Traffic Staff Technical v/s Commercial & Traffic Staff directly involved in running of trainsdirectly involved in running of trains

Signal & Telecommunication

ControllersElectrical /ACGuardsBridgesDriversAccount / AuditPermanent wayYard StaffTTEsDiesel / Electric LocoStation mastersBooking clerksC&W TrafficCommercialTechnical

RECRUITMENT, QUALIFICATION AND RECRUITMENT, QUALIFICATION AND TRAININGTRAINING

JUNIOR ENGINEER (GP 4200)

50% - Direct recruitment through RRB 3 Years Diploma in Engineering &1 ½ Years In- plant training.

(Total 4 ½ Years Qualification equal to Engineering degree)

VI CPC observation that JE and Clerk are equal since both have 3 years Qualification is wrong since JE has total 4 ½ years Qualification.

Hence both pay cannot be equal and needs correctionHence both pay cannot be equal and needs correction.

JUNIOR ENGINEER JUNIOR ENGINEER Cont..Cont..

The Duties and Responsibility of a JE is enormous when compared to a clerk with whom he is equated.JEs in open line bears highest responsibility in safe running of trains.Have a direct element in running of trains along with drivers.Driver’s function start only after the issuance of BPC by Open line engineer

SECTION ENGINEER / Sr.SECTION SECTION ENGINEER / Sr.SECTION ENGINEERENGINEER (GP 4600)(GP 4600)

Both scales merged as SSEComposition of cadre– 20% Direct recruits with 4 / 4 ½ years Degree in Engineering

and One year In-plant training– 80% promoted from Junior Engineers (4 ½ Years total

qualification and 20 to 25 years of Experience)VI CPC observation that this category is equal to any other Bachelor degree holder in arts, science or commerce is totally wrong.SSE with such huge responsibility and accountability and Office Superintendent cannot be kept in same scale in any angle of observation

AVENUES OF PROMOTIONAVENUES OF PROMOTION

Only one promotion for JE-II/JE- I from 4200 Grade Pay to SE/SSE with 4600 Grade Pay.

No promotion for SE/SSE with 4600 Grade pay and must retire in same grade.

Only about 2% of Technical Supervisors in Indian Railways get promoted as Group – B officers.

Even after this analysis submitted Even after this analysis submitted in this study, if one decides that in this study, if one decides that

JE = ClerkJE = ClerkSSE = OSSSE = OS

Then GOD only can save railwaysThen GOD only can save railwaysand only GOD need to be and only GOD need to be

appointed as Pay commission appointed as Pay commission chairmanchairman

Observation by IRTSA