Draft Report on Infrastructural ... - Indian...

Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line

Government of India Ministry of Railways

Draft Report on

Infrastructural Facilities for Maintenance of LHB Coaches in Open Line

CAMTECH/2016/M/LHB-INFRA/Open-line/1.0 May – 2016

(For official use only)


Draft Report on

Infrastructural Facilities for Maintenance of LHB Coaches in

Open Line


Preface

At present, Indian Railways has a large holding of LHB type Coaches and also

increasing day to day due to better features and efficiency than ICF/RCF coaches.

There is need a change in infrastructure of Coaching depots to efficient and proper

maintenance of LHB Coaches for better performance and passenger safety.

This Report is prepared with the objective to provide informative technical details

on Infrastructure for LHB Coach maintenance for the guidance of Mechanical

engineers involved in maintenance of Coaching stock. It covers the constructional

features of pit line, lay out drawing of pit line without cat walk & with Automatic

coach washing plant, M&Ps required, Tools and equipments, flooring, EOT cranes

& type of sheds and its length etc..

This Report does not supersede any existing instructions from Railway Board,

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

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

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

and Coaching Depots on IR.

We welcome any suggestions from our readers for further improvement.

CAMTECH/Gwalior (K.P.Yadav)

Date : 02.05.2016 Director/Mech.


Contents

S.N Description Page No.

1. Objectives 1

2.

New design of pit line without catwalk and with ACWP

(Automatic Coach Washing Plant) with water recycling

treatment plant

1

3. Twin depth pit line 3

4. Modern equipments 3

5. Other facilities 3

6. Coaching Depot Layout for LHB 3

7. Data/details of layout of coaching complex 5

8. Features of maintenance bay 7

9. Features of maintenance bay

(pit line without catwalk without shed)

8

10. Features of Maintenance bay (Pit line with side catwalk

and without shed)

9

11. A view of pit line at DMRC on steel pillars: 10

12. Maintenance bay showing ramp, stairs & pillars: 11

13. Service room & space for vehicle & machinery: 12

14. Features of IOH depot (maintenance sick line): 13

15. Maintenance sick-line for LHB 14

16. Details of infrastructure facilities proposed for

primary maintenance depot (LHB coaches EOG)

15

17. Some modern equipments 30

18. Automated Wheel Diagnostic System (WDS) 30

19. Mobile lifting platform 33

20. Coach Lifting System 34

21. Wheel Changing System 35

22. Automatic in-motion train washing system (ACWP) 36

23. Layout and construction of automatic coach washing

plant

38

24. Process of coach cleaning and washing in different stages 41

25. Water recycling treatment plant. 45

26. Internal coach cleaning machine 47

27. Transportation Codes for LHB Coaches 48

28. Suggestions given by Zonal Railways during seminar on

21.07.2014 & 20.07.2015

49


ISSUE OF CORRECTION SLIPS

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

numbered as follows:

CAMTECH/2016/M/LHB INFRA/Open line/1.0/CS. # XX date

...………….......

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

(starting from 01 onwards).

CORRECTION SLIPS ISSUED

Sr. No. of

C.Slip

Date of

issue

Page no. and Item No.

modified

Remarks

CAMTECH/2016/M/LHB INFRA/Open line/1.0 1


1.0 OBJECTIVES:

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

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

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

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

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

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

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

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

construction and are economical as well.

2.0 NEW DESIGN OF PRE-FABRICATED PITLINE WITHOUT

CATWALK AND WITH ACWP (AUTOMATIC COACH WASHING

PLANT & WATER RECYCLING PLANT)

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

Railway on the basis of recommendations made by CAMTECH and

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

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

washing/ cleaning operation of coaches during maintenance. During

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

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

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

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

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

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

having pit lines without catwalks.

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

cleaning, adequate number of movable trolleys/forklifts with suitable

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

washing may also be reviewed in such cases.

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

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

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

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

without cat walk.

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

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

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

CAMTECH/2016/M/LHB INFRA/1.0 2


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

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

ACWP with water recycling plant has been considered necessary for outside

cleaning of the coaches. This will reduce the efforts and time taken at the pitline

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

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

noticed that coach washing plants which are in use on Indian Railways are not

working properly due to various reasons. It is, therefore, proposed that a washing

plant of a specification equivalent to one available at PA coaching depot should

be provided.

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

considered in place of separate facilities for internal cleaning of coaches and

repair/examination of coaches. It has been noticed that if separate facilities are

provided, the time taken in shunting is 1-2 hours and thus the cycle time increases

considerably. The very purpose of this exercise i.e. to reduce the maintenance

time gets defeated. Further, since ACWP has been provided, the coach washing

will anyway be done at the entry point of the pitline, therefore, spillage of water

on pitline will be reduced to a great extent. This will serve the purpose of keeping

the pit dry to a great extent.

2.1 Merits and Demerits of Catwalk

SN Disadvantages of Catwalk Advantages of without Catwalk

01 Clumsy lay out Less clumsy lay out

02 Day Light is restricted Plenty of daylight is available

03 Cross movement is also restricted Easy movement of maintenance staff

2.2 Unified pit line: The unified pit line should be as per RDSO‟s drawing number

RDSO/M-00006/R1&R2 revised in October-2011(This Drawing is fit for entry of

Locomotive with 30 kmph.) or CAMTECH‟s report no. CAMTECH.M.Infra.99/1.0

(This Drawing is unfit for entry of Locomotive.) depending upon whether loco

movement is required or not on the pit line.

2.3 ACWP: Automatic coaches wash plant as per COFMOW‟s specification number

COFMOW/IR/M-CWP/2010 or latest.

2.4 WATER RECYCLING PLANT: Water conservation has become need of the hour

due to finite source of supply of water due to which water level is depleting

continuously. The water recycling in Railway coaching depots may help in conservation

of water. The NCR has already installed water recycling treatment plant in ALD Division

and has reported satisfactory performance. Railway Board vide letter No.

2015/M©/135/2(3) dated 30.01.2015 has also communicated one letter to RDSO for

judging the performance.



3.0 Twin depth pit

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

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

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

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

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

drain for this purpose.

4.0 Modern Equipments

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

facilities for examination, repair and maintenance of coaches, following

modern equipment may be recommended by Railway Board:-

Automated Wheel Diagnostic System

Mobile Lifting Platform

Bogie/Car body lifting System

Waste removal system for Bio-Toilets/Vacuum Toilets

Automatic in-motion Train Washing System

Water recycling treatment plant

Bogie turn table.

5.0 Other Facilities

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

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

have also been proposed.

6.0 Layout

6.1. The coaching depot is planned for 28 LHB coach length rake.

6.2 The coaching depot consists of

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

b) Automated wheel diagnostic system (WDS)

c) Maintenance bay (Pit-line)

d) Maintenance Sick line (under covered shed)

e) Service rooms

f) Stabling line

g) Shunting neck



6.3 Sequence of operation

(a) Train entering into the coaching depot

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

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

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

safety examination

(f) Pulling the rake in shunting neck

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

Ref: Sketch-01



7.0 Data/detail of layout of Coaching Complex

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

(b) Width of the Coaching Complex = 120 m

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

(b) Height of boundary wall = 2 m

(c) Length of boundary wall = 4000 m

7.3 (a) Width of road = 5 m

(b) Length of road = 2285 m

7.4 (a) Total track length = 6 km

(b) Number of points and crossings = 9 sets

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

(b) Length of the maintenance bay = 675 m

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

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

(b) Length of maintenance Sick line = 200 m

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

7.7 (a) Width of Service rooms = 5m

(b) Construction of Service building = as per detail

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

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

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

Ref: Sketch-01



8.0 Features of maintenance bay

8.1 Data/dimensions :

(a) Length of maintenance bay = 675 metres

(b) Width of maintenance bay = 14.49 metres

(c) Capacity = 2 rakes

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

schedule maintenance of under gear and upper gear.

8.3. Main features of the maintenance bay are -

a. Broad and obstacle free pathways.

b. Under pit pathway below the rake/track.

c. Pit line on metallic (steel) pillars.

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

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

f. Provision of service rooms.

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

h. Provision of compressed air pipe line.

i. Provision of overhead light.

j. Provision of under pit light.

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

8.4 Other salient features:

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

underground.

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

of each coach.

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

foundation design of load bearing items.

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

considerations.



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

9.1. Data/dimensions :






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

10.1. Data/dimensions :




Covering features of both pitline with catwalk and without catwalk

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

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

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



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



12.0 Maintenance bay showing ramp, stairs & pillars:

Sket

ch N

o. 4

Prep

ared

By

CA

MT

EC

H/G

wal

ior



13.0 Service Room & Space for Vehicle & machinery:

3. A

ll ro

oms a

re fi

tted

with

stan

dard

ele

ctric

al fi

tting

s of

sui

tabl

e an

d ap

prop

riate

qua

ntity

and

qua

lity

SER

VIC

E R

OO

M A

ND

SPA

CE

FOR

VEC

HIL

ES A

ND

MA

CH

INER

IES

1. T

he s

ervi

ce ro

oms a

re lo

cate

d in

bet

wee

n m

aint

enan

ce b

ay a

nd m

aint

enan

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orks

hop

serv

ing

at o

ne si

de to

mai

nt.b

ay a

nd a

t oth

er si

de to

mai

nt.w

orks

hop.

Exam

inat

ion

pit

Veh

icle

Spa

ce

2. A

ll ro

oms a

re h

avin

g do

ors,

win

dow

s an

d ra

cks e

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f sta

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men

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s.

4. T

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etch

doe

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ruct

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and

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datio

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tail

of th

e ro

oms.

2 55 2

Spac

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r ser

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, veh

icle

and

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Mai

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Bay

30

Sket

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CA

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14.0 Features of IOH Depot (Maintenance Sick Line):

1. Data/dimensions :

(i) Length of maintenance sick line = 200 metres

(ii) Width of maintenance sick line = 19.5 metres

(iii) Capacity = 2 lines

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

coaches and for attending higher maintenance schedules of the coaches.

3. Main features of the maintenance sick line are:

a. Provision of 04 LHB coach length examination pit – One on each

line.

b. Provision of wheel profile lathe.

c. Provision of bogie/coach lifting system.

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

fork lifter, hoist, bogie turn table.

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

f. Provision of wheel parking.

g. Provision of covered shed.

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

fixed and portable machines and equipments

NB : 1) The sketch of maintenance sick-line does not have structural and

foundation design of load bearing items.

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

design considerations.

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

installed suitably.

Ref: Sketch No. 05 & 06



15.0 Maintenance Sick-line:

CAM

TECH

/Gwa

lior

Prep

ared

By

Sketc

h No.

6



16.0 DETAILS OF INFRASTRUCTURE FACILITIES PROPOSED FOR

PRIMARY MAINTENANCE DEPOT (EOG LHB Coaches)

A. Infrastructural Facilities & Building:-

S.N. ITEMS COACH HOLDING

0-50 51-100 101-250 251-500 501-1000

1. Covered shed (Sick Line) 1 1 1 1 1

2. Maintenance lines with pit (No. of lines

x No. of coaches)

1 x 2 1 x 2 2 x 2 2 x 4 2 x 6

3. Wheel line 1 1 1 1 1

4. Linen store room, size 5m x 15m

5. Battery room with battery beds Size 5m

x 10m

1 1 2 2 2

6. Room for storing cleaning equipment,

size 5m x 10m

1 1 1 1 1

7. Mech. item repair room with test

benches, size 5m x 10m (DV, Brake

cylinder, Bio-Toilet/CDTS etc.)

1 1 2 2 2

8. Mechanical millwright room, size 5m x

10 m

- 1 1 1 2

9. Computer room, size 5m x 5m - 1 1 1 1

10. Diesel engine overhaul shed with 5T

EOT crane (2 each)

1

12m

x

15m

1

12m x

25m

1

12m x

30m

1

12m x

45m

1

12m x

60m

11. Pantry equipment repair room, size 5m

x 10m

1 1 2 2 3

12. Power car equipment testing room with

suitable test benches, size 5m x 10m

1 1 2 2 3

13. Switch gear test room, size 5m x 10m 1 1 2 2 3

14. Fan/Light fittings repair room, size 5m

x 5m

1 1 2 2 3



S.N. ITEM COACH HOLDING

0-50 51-100 101-250 251-500 501-1000

15. Electric motor repair room, size 5m x

5m

1 1 2 2 3

16. RMPU Simulator training room, size

5m x 10m

1 1 1 1 1

17. Staff training room facilities including

projector, LCDTV, video camera, DVD

handycam & other modern teaching aids,

Size 5m x 10m

- 1 1 1 1

18. Radiator cleaning room with necessary

facilities, size 5m x 5m

- 1 2 2 2

19. Engine sub assemblies repair room with

repairing & calibration facilities, size

5m x 10m

1 1 2 2 2

20. Tool room with shelves and almirahs,

size 5m x 10m

1 1 2 2 2

21. FIP pump & injector repair room (AC)

with testing and caliberation facilities,

size 5m x 5m

1 1 2 2 3

22. Inductive load (500kW) testing room

with test benches, size 5m x 5m

1 1 1 1 1

23. Dynamo meter (500kW) test room with

suitable test benches

1 1 1 1 1

24. 50/60-kVA transformer repairing room

with testing facilities, size 5m x 10m

1 1 2 2 3

25. I.V. coupler/ HOG coupler# & ratchet

wheel repair room with test facilities,

size 5m x 5m

1 1 1 2 2

26. Main Store with Unit Exchange Spares

with material storing facility (size 5m x

10m) for Electrical & Mechanical

separately.

2 2 4 4 6

27. Shift/ Custody stores with material

storage facility (size 5mx5m) for

Electrical & Mechanical separately.

2 2 2 2 4

28. Scrap material room/shed of adequate

size as per requirement.

1 1 1 1 1




0-50 51-100 101-250 251-500 501-1000

29. Storing facility for Lube, HSD,

Kerosene oil, size 5m x 5m

1 1 1 2 2

30. Storing facility for refrigerants, DA &

oxygen, Nitrogen, size 5m x 5m

1 1 1 2 2

31. Depot officers Gazetted room, size 5m

x 5m

-- 1 JS 1 SS 2

JS & SS

4

(1JA, 1SS,

2JS)

32. In charge/ SSEs/JEs office, size 5m x

5m

1 2 2 4 6

33. Establishment office, 5m x 10m - 1 1 1 1

34. PPIO office, size 5m x 5m -- 1 1 1 1

35. Material management office, size 5m x

5m

-- 1 1 1 1

36. Scooter & cycle stand of adequate size 1 1 1 1 1

37. Conference room of adequate, size 25m

x 10m

-- -- 1 1 1

38. Staff room with lockers size 5m x 10m 1 1 2 2 3

39. Staff room for ladies, size 5m x 5m 1 1 1 2 2

40. Separate toilets for gents and ladies. 2 2 4 4 6

41.

Electronic lab (AC) with all repair and

testing facilities

size 5m x 5m

-- 1 1 1 1

42. Staff Canteen of adequate size. - 1 1 1 1

43. Vehicle repair room, size 5m x 10m

44. Room for various meter testing and

calibrating facility, size 5m x 5m.

-- 1 1 1 1

# Applicable for HOG system



B. Mechanical (M&P) at Sickline

S.N. ITEM 0-50 51-100 101-250 251-500 501-1000

1. Automatic coach washing plant

(ACWP) with water recycling

- - - 1

1

2. Wheel diagnostic system (WDS) - - - 1 1

3. Coach lifting system - - 1 1 1

4. Wheel profile lathe 1 1 1 1 1

5. Synchronized electrically

operated Whiting Jacks of 15 T

capacity

2 2 4 6 8

6. Welding plant (portable) Single

phase 230 V 1 2 3 4 5

7. Welding plant (Stationary) 3 Ph.

440 V

- 1 2 2

3

8. Air compressor-350 cfm with air

dryer (Diesel) 1 1 1 2 2

9. Air compressor-350 cfm with air

dryer (Electric)

1 1 1 1

1

10. EOT crane 20/10T in

maintenance sick line

1 1 1 2 2

11. Floor scrubber 02 02 04 05 06

12. Dry & wet vacuum cleaner 02 02 04 05 06

13. Mobile jet cleaner 04 06 08 10 12

14. Drainage pump heavy duty 5HP

(Muck pump centrifugal)

1 1 1 2

2

15. Sewing machine 1 1 1 2 2

16. Portable pump 1 1 1 2 2

17. Gas welding-cutting set 1 2 3 4 5

18. Lathe machine, 1000mm between

centre complete including spares

and accessories with attachment

for precision grinding and tapering.

1 1 1 1 1

19. Bench vice 1 2 3 4 5

20. Medium sized electric motor

driven pillar drilling machine

complete.

1 1 2 2 2

21. Heavy-duty motor driven

pedestal grinder complete.

1 1 1 2 2

22. Portable electric motor driven

drill machine.

1 2 3 4 6


grinder.

1 1 2 4 5



S.N. ITEM 0-50 51-100 101-250 251-500 501-1000

24. Electric motor driven Winching

machine for movement of

coaches of suitable capacity

1 1 1 2 2

25. 46.7 Ltrs spare oxygen (7 m3

) gas

cylinders

2 2 3 4 6

26. 41 Ltrs spare Acetylene (5.5 m3

)

gas cylinders

2 2 3 4 6

27. Hand tools for coach maintenance

staff

As per

require

ment

As per

require

ment

As per

requirem

ent

As per

requirem

ent

As per

requireme

nt

28. Maintenance staff tool boxes

with tools.

For

each

tech.

For each

technici

an

For each

technicia

n

For each

technicia

n

For each

technician

29. Pipe bending machine for air

brake SS pipes

1 1 1 1 1

30. Inverter based AC/DC TIG

welding machine

1 1 1 1 2

31. Synergic pulse Tag welding

plants

2 4 6 8 10

32. Synergic Tag welding plant 1 1 2 2 2

33. Welding rectifier 1 1 1 1 1

34. Air plasma cutting machine 1 1 1 2 2

35. Pick & carry mobile crane 10

tonne

1 1 1 2 2

36. Hydraulic material carrying and

lifting system – For lowering and

carrying of CBC

1 1 1 2 2

37. Milling machine 36x8 Gear head - 1 1 1 1

38. Walk behind power vacuum

sweeper

- - 1 1 2

39. Pendulum action jig saw machine - - 1 1 1

40. Test bench for brake control panel 1 1 1 1 1

41. Square drive torque wrench 1”

male square drive for fastening of

Nuts and bolts of Bogie frame.

1 1 1 1 1

42. Hydraulic torque wrench – For

Nuts and bolts of Bogie frame

1 1 1 1 1

43. Torque wrench (ratchet) torque

38 Kg-m sq. drive ¾”

1 1 2 4 4

44. Torque wrench (ratchet) torque 3-

14 Kg-m sq. drive ½”

1 1 2 4 4



S.N. ITEM 0-50 51-100 101-250 251-500 501-1000

45. Torque wrench (ratchet) torque 7-

35 Kg-m sq. drive ½” and ¾”

1 1 2 4 4

46. Gauge for checking Bearing

Mounted End Play.

1 1 1 1 1

47. Bench end-play checking fixture. 1 1 1 1 1

48. Fixture for bearing lubrication 1 1 1 1 1

49. Spring testing machine for

Load/Deflection

1 1 1 1 1

50. Testing machine for Yaw

dampers.

1 1 1 1 1

51. Vernier dial calliper 0-300 mm 1 1 1 1 1

52. Vernier calliper 0 – 600 mm 1 1 1 1 1

53. Vernier Calliper 0-2000 mm- For

inspection of bogie frame

1 1 1 2 2

54. Vernier height gauge 18” 1 1 1 1 1

55. Vernier calliper (digital) 1 1 1 1 1

56. Micrometer digimatic range 125

to 150 mm

1 1 1 1 1

57. Micrometer digimatic range 150

to 200 mm

1 1 1 1 1

58. Digimatic inside micrometer

tubular range 175 to 200 mm

1 1 1 1 1

59. Inside micrometer range 175-225

mm

1 1 1 2 2

60. Digimatic inside micrometer

tubular range 200 to 225 mm

1 1 1 1 1

61. Dry film thickness measuring

equipment

1 1 1 1 1

62. Gloss meter 1 1 1 1 1

63. Surface roughness comparator 30

specimens

1 1 1 1 1

64. Bench pillar drilling machine 1 1 1 1 1

65. Portable hand drill machine 1 1 1 2 2

66. Tool cabinet As per

require

ment

As per

require

ment

As per

require

ment

As per

require

ment

As per

requirem

ent

67. Material handling crate --do-- --do-- --do-- ---do-- --do--

68. Cleaning sink As per

req.

As per

req.

As per

req.

As per

req.

As per

req.



S.N. ITEM 0-50 51-100 101-250 251-500 501-1000

69. Impact spanner --do-- --do-- --do-- ---do-- --do--

70. Pallet trolley --do-- --do-- --do-- ---do-- --do--

71. Feeler gauge --do-- --do-- --do-- ---do-- --do--

72. Allen key set as per list --do-- --do-- --do-- ---do-- --do--

73. One meter stainless steel scale --do-- --do-- --do-- ---do-- --do--

74. 12” stainless steel scale --do-- --do-- --do-- ---do-- --do--

75. Measuring taps 03 mtrs. --do-- --do-- --do-- ---do-- --do--

76. Steel rule --do-- --do-- --do-- ---do-- --do--

77. Heavy duty rechargeable torch --do-- --do-- --do-- ---do-- --do--

78. Trestle for stabling coach body --do-- --do-- --do-- ---do-- --do--

79. Press for pressing body wall --do-- --do-- --do-- ---do-- --do--

C. M&P and tools required at Pit line.

1. Tool kit (Torque wrenches, Allen keys, pliers, spanners set etc.)

2. High pressure jet cleaning machine.

3. Axle dia measurement gauge/micrometer.

4. GO/NO GO threads plug gauge for axle ends.

5. Parallelism checking tool for control arm.

6. Equipment for pneumatic System Functional Test.

7. Single car testing rig for air brake system.

8. Mounting/ dismounting tools for Anti roll bar bearing.

9. Mounting/ dismounting tools for Anti roll bar elastic joint.

10. Miner pad pressing Fixture

11. Inspection torches

12. Spiked hammers

13. Ball peen hammers

14. Goggles for inspection staff

15. Measuring tape

16. Measuring scale

17. Gas cutting plants

18. Multi-operator welding plants

19. Electrical angle grinders

20. Pneumatic hand grinders



D. Testing Facilities (Mechanical)

S.N. ITEM 0-50 51-100 101-250 251-500 501-1000

1. Air brake rake test rig 1 1 2 4 6

2. Single car test rig (SCTR) 1 1 2 4 6

3. Water tank test rig 1 1 1 1 1

4. Ultrasonic testing apparatus 1 1 1 1 1

5. DV test bench 1 1 1 1 1

6. Test facility for CDTS/Bio-Toilet 1 1 1 1 1

7. DP test facilities 1 1 1 1 1

8. WSP test feacilities 1 1 1 1 1

E. Material handling equipments

S.N. ITEM 0-50 51-100 101-250 251-500 501-1000

1. Fork lifter 3T 1 1 2 2 2

2. Fork lifter 1.5T 1 1 2 2 2

3. Lister 1.5T 1 2 4 6 8

4. Mobile lifting platform 2 4 6 10 12

5. Hydraulic pallet truck 01T

capacity

1 1 2 4 6

6. Lorry truck - 1 1 1 1

7. Pick up Van - 1 1 2 2

8. Push type/ Hand trolley 500 kg 2 2 4 6 6

9. Material van - 1 1 2 2



F. Safety Equipments


0-50 51-100 101-250 251-500 501-1000

1. All workmen safety equipments such

as industrial helmets, hand gloves,

industrial shoes, masks, minor lamp

etc.

As per requirement

2. Fire extinguishers, water hydrants,

sand buckets with stand As per requirement

3. Safety belts As per requirement

4. FFiirrsstt aaiidd bbooxxeess As per requirement

G. Other facilities

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

should be provided judiciously to avoid wastage of resources.


0-50 51-100 101-250 251-500 501-1000

1. Computer (PC) with printers to analysis

TL & AC failures & records and LAN

facility

2 4 6 8 10

2. Fax machine 1 1 1 1 1

3. Photo stat machine with Scanner 1 1 1 1 2

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

phones/ intercom and other

communication facilities

As per requirement

5. Water Cooler with purifier As per requirement

6. Storage racks, almirah, locker, furniture

etc As per requirement

7. Bins, container etc As per requirement



H. ELECTRICAL TOOLS, MACHINES & PLANTS

(Ref: CAMTECH Maintenance Manual for LHB Coaches Annexure-11.9 of Chapter 11)

The facilities mentioned below are bare minimum. However, if some facilities are

already available (either in mechanical or electrical sick line) only supplementing would be

necessary. Effort should always be made to complete both electrical and mechanical

maintenance in single placement of the rake.

I. REPAIRING & TESTING FACILITIES


0-50 51-100 101-250 251-500 501-1000

1. Engine sub assemblies repairing &

calibration facilities

1 1 2 2 3

2. FIP pump & injector repairing, testing

and calibration facilities

1 1 2 2 3

3. I.V. coupler/ HOG coupler & ratchet

wheel repairing and testing facilities

1 1 1 2 2

4.

Filter cleaning arrangements with

blower & water sump for cleaning/

drying air filters

1 1 2 2 2

5. Radiator cleaning tank size 2W x 4L

x 2D (in meters).

-- 1 1 1 1

6. Microprocessor based Electronic card

reading and repairing facilities.

-- -- 1 1 1

7. HSD oil decantation facility with

pump for generator car shed of

suitable capacity.

-- 1 1 1 1

8. 500 kW load testing facility for power

car (Inductive/ Resistive)

1 1 2 2 2

9. Test bench for Diesel engine

(Dynamometer type)

1 1 2 2 2

10. Test bench for on load testing of

Alternator of power car

-- -- 1 1 1

11. Testing supply points 750V 3 phase At each coach length

12. Portable Step up transformer 415/750,

50/60kVA

1 1 2 2 4




0-50 51-100 101-250 251-500 501-1000

13. Test bench for testing relays &

contactors

1 1 2 2 2

14. Power supply analyzer, oscilloscope

dual channel, storage type

1 1 2 2 2

15. Testing facility of RBC and

emergency battery charger

1 1 1 2 2

16. Mono-block pump testing facility 1 1 1 2 2

II. MACHINE & PLANT


0-50 51-100 101-250 251-500 501-1000

1. Arial lifting platform for climbing on

roof of coach. 1 1 2 2 3

2. EOT crane 10T 1 1 2 2 4

3. Mobile Jib crane mounted on lister

1.5T

1 1 2 3 4

4. Distilled water plant – preferably

solar system, (in ltrs per day)

1x 100

lpd

1 x 100

lpd

1 x 500

lpd

2 x 500

lpd

2 x 500

lpd

5. Portable Transformer type arc

welding set complete.

1 1 2 2 3

6. Hydraulic operated scissor – type

platform truck of 1T capacity.

1 1 2 2 3

7. Vacuum pump with gauges etc. 1 1 2 4 6

8. Portable high pressure water jet

washing machine with electric motor

driven pump.

2 2 4 4 6

9. Gas cutting set 1 1 2 2 4

10. Battery charger sets suitable for

440V, 3 phase, 50Hz AC input &

110V, 200A DC current complete

with accessories for charging

batteries

2 2 4 4 6

11. Pre cooling sockets with universal

type connector.

At each coach length.




0-50 51-100 101-250 251-500 501-1000

12. Regenerative type Constant current

constant voltage battery charger for

2 mono blocks

1 1 2 2 2

13. Portable battery charger up to 15

amps. Capacity

1 2 2 4 4

14. Battery analyzer 1 1 1 1 2

15. Motor driven portable air

compressor set with reservoir of

suitable capacity

1 1 2 2 4

16. Lathe machine, 1000mm between

center complete including spares

and accessories with attachment for

precision grinding and tapering.

-- -- 1 1 1

17. Dynamic balancing machine for

balancing of fans, shafts &

alternator pulley.

1 1 1 1 1

18. Medium sized electric motor driven

pillar-drilling machine complete.

1 1 2 2 2

19. Bench vice 2 2 4 4 6

20. Heavy-duty motor driven

pedestal grinder complete

1 1 2 2 2

21. Hydraulic puller 50T -- -- 1 1 1

22. Hydraulic puller 10T 1 1 2 2 4

23. Hydraulic press machine 2T -- 1 1 1 2

24. Portable electric motor driven drill

machine

2 4 6 8 10


grinder

1 2 3 4 5

26. Escorting staff tool boxes with tool

kit as per RDSO

For each escorting technician

27. Digital Megger upto 2.5 kV 1 2 2 4 4

28. Vacuum cleaner industrial type 1 2 2 4 4

29. Refrigerant recovery plant 1 1 2 2 4




0-50 51-100 101-250 251-500 501-1000

30. Electronic weighing machine up to

15kg

1 1 2 2 3

31. Electronic weighing machine up to

500kg

1 1 2 2 3

32. Testing equipment (variable voltage

supply AC & DC, transistor tester,

meter testing kit etc.)

2 2 4 4 6

33. Electric motor driven de-watering

pump set for pits.

1 1 2 2 2


blower

2 2 4 4 6

35. 46.7 Ltrs spare oxygen (7 m3 )

cylinders

2 4 4 8 15

36. 41 Ltrs spare Acetylene (5.5 m3 )

gas cylinders

2 4 8 8 15

37. 46.7 Ltrs spare Nitrogen (7 m3 ) gas

cylinders

2 4 8 8 15

38. Spare refrigerant cylinders 4 6 8 10 15

39. Oven for drying electrical motor etc.

size as per requirement.

1 1 1 1 1

40. DG set, 415V of adequate capacity as

standby power supply.

1 1 1 1 1

41. Step up transformer 415V/ 750 V of

adequate capacity as standby power

supply.

1 1 1 1 1

42. 415V/ 750 V power supply points

along the pit

At each coach length

43. Injector testing & calibration

machine.

1 1 2 2 2

44. Injector leakage testing machine 1 2 2 4 6

45. Hot air Gun 1 1 2 2 2

Note: Air quality measurement facility and DG set exhaust air pollution check facility

have been withdrawn due to high value items as discussed in the meeting held at

Jagadhari workshop on 19.04.2012.



II. TOOLS


0-50 51-100 101-250 251-500 501-1000

1. Set of Miscellaneous tools:

Torque wrenches

Special spanner

Soldering iron

De-soldering pump

Manual cable crimping tool Hydraulic

crimping tool

Cable stripper

Cable cutter

Pliers

Screw drivers

Line tester

Cell tester

Test lamp

Hammers

Mallets

Riveting tool

Punching tool

5

sets

5

sets

10

sets

10

sets

15

sets

2. Set of Measuring tools:

Dial indicators

Filler gauge sets

Vernier calipers

Vernier micrometers

Torque wrench

Depth gauges

Screws gauge

Go/No Go gauges

Hydrometer etc.

2

sets

2

sets

5

sets

5

sets

10

sets

3. Set of Special tools for RMPU:

Refrigerant leak detector

Tube cutters

Pinch off tool

Flaring tool

Charging line

Hand shut off valves

Combination gauge

Air flow meter

2

sets

2

sets

5

sets

5

sets

10

sets



Contact less thermometer

LP gauge

HP gauge

Tube bender

Lapping machine

4. Set of Electrical testing tools:

Digital multi meters

Industrial grade AC & DC voltmeters

Industrial grade AC & DC ammeter

Digital tongue tester

Insulation tester

Contact less thermometer

Digital thermometer

Infrared thermometer

Non contact type digital tachometer

Anemometer

Hygrometer

Lux meter

2

sets

2

sets

5

sets

5

sets

10

sets

5. Digital dB meter (Noise level

indicator)

2 2 2 4 6

6. Shock pulse meter 1 2 3 4 6

7. Techo meter 1 1 1 2 2



17.0 SOME MODERN EQUIPMENTS

a. Automated Wheel Diagnostic System (WDS)

b. Automatic in motion Train Washing System

c. Water recycling treatment plant

d. Mobile Lifting Platform

e. Bogie/Car body lifting system

f. Under floor bogie repair hoist

g. Turn table

h. Waste removal system for Bio-Toilet

18.0 Automated Wheel Diagnostic System

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

motion inspection and testing unit for the diagnosis of wheels of

vehicles in operation.

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

work :-

a. Vehicle/wheel set identification

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

out of roundness

c. Detection and measurement of flat spots

d. Measurement of tread diameter and detection of overshooting

of operational tolerances

e. Measurement of wheel profile and detection of overshooting of

operational tolerances

f. Detection of cracks

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

P.O. Box 1652-D-41806 Erkelenz

Website : www.hegenscheidt-mfd.de

Fax- 0049(0) 2431 86 470

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

16-A, Palam Marg, Vasant Vihar

New Delhi-110057

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

Mobile no. 09810421620

2. SAB Wabco

Cost : Rs.5.0 Crores

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



18.1 Technology:

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

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

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

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

electrical equipments and high resolution digital cameras and

computers which are capable of accurately processing the digital

data, the wheel profile measurement can be performed.

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

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

between the track and the wheel crown is continuously measured

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

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

between largest and smallest diameter will give the measurement of

out of round.

CC.. CCrraacckk ddeetteeccttiioonn

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

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

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

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

wheels. This will help in -

Average planning of wheel profiling and wheel change.

Improved safety and reliability

Improved wheel life.

Reduction in examination time and manpower.

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

(Photograph on next page)



18.2 Photograph of Wheel Diagnostic System

18.3 Layout of Wheel Condition Monitoring System

Inrail installed wheelset diagnostic system

Wheel Condition Monitoring System •

Identi - fication

roundness and

flat spot

basic module

diameter cracks profile and

back to back

database

Remote access

Data exchange

Inrail I nstalled wheelset diagnostic system

Wheel Condition Monitoring System •

Identi - fication

roundness and

flat spot

basic module

diameter cracks profile and

back to back

database

Remote access

Data exchange

In Rail Installed Wheel Set Diagnostic System



19.0 Mobile Lifting Platform

(Aerial work lift platform)

Description : Battery powered aerial work lift platform with hydraulically

operated scissor lifts.

Source of supply : 1. JLG Industries Inc

1- JLG Drive,McConnellsburg,PA, USA

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

Mobile no. 09810119569.

2. NeueroTechnologies GmbH, Germany

Cost : Rs.15 Lakhs



20.0 Coach lifting system

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

body stand.

Source of supply : 1. Neuero Technologies GmbH

Germany

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

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

New Delhi-110019 Tel. 011-26271369, 26276449

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

Mobile no. 09810158226

2. M/s Pfaff

D-86316, Friedberg/Derching,Germany


Lifting Jacks: 1. Jamalpur Workshop, Jamalpur

20.1 Photograph of Coach Lifting System



21.0 Wheel changing system

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

Source of supply : 1. Neuero Technology

Germany

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

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

New Delhi-110019 Tel. 011-26271369,26276449

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

Mobile no. 09810158226

2. Windhoff, Germany


20.1 Photograph of Wheel changing system



22.0 Automatic in-motion train washing system (ACWP) with water

Recycling plant.

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

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

vertical and horizontal rotating brushing unit .

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

2. M/s Bingham - UK

3. Kokan Railway

Cost : Rs………

22.1 Photograph of Automatic in motion train washing system

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

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

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

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

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

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

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

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

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

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



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

the desired level of cleanliness cannot be done satisfactorily by

conventional method within limited time period.

22.2 AUTOMATIC COACH WASHING PLANT

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

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

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

washing plant is developed. In this plant, external cleaning of coaches of a

rake was done at PA, Madgaon & Kurla by horizontal rotating nylon

brushes while passing through.

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

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

1.Stages of

a) Pre-wash,

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

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

incorporated in this washing plant.

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

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

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

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

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

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

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

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

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

to be cleaned manually by available staff.

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

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

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

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

within 35-40 minutes.

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

conventional Manual coach cleaning.

e) Reduction in power consumption by using automation.

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

pressure jets.

g) Bogie side cleaning by high pressure jets.



h) Roof cleaning of Coach by horizontal nylon brush.

23.0 LAYOUT AND CONSTRUCTION OF AUTOMATIC COACH

WASHING PLANT

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

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

this washing plant.

1) First structure is having plan

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

and provided for PREWASH

stage. This structure is erected

at a distance of 30 meter from

second structure, to get

complete soaking of coach

with water.

2) Second structure is having

plan area of 8.16 sq.mtr.(2.4m

X 3.4m), is made from 300 x

150 mm ISBM & 300 x 90

mm „C‟ channel This

structure is provided for the

stages of SPRAYING OF

SOAP SOLUTION and

Rubbing Of Soap Solution by

vertical nylon brushes.

3) Third structure of underneath

pipelines along with air and

water reservoirs having plan

area of (4.5mX3.4m)

15.3sq.mtr. and it is provided

at distance of 16mtr. from

second structure. This

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



4) Fourth structure is having plain area of

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

for the stages of a) Moistening of soap

solution b) Roof cleaning by a

horizontal nylon brush c)Side cleaning

by four vertical cotton brushes. d)

After wash with high pressure jets.

e)Mopping by two vertical cotton

brushes. and Fourth structure is

erected at distance of 23 mtr. from

second structure, to get sufficient time

for reaction and complete soaking

with soap solution. near washing

plant.

This structure is located at start of pit line

is aligned and extended to old existing

structure of coach washing plant. It is

also made from same material used for

second structure. Central apron already

exists between the structure & track. It is

provided with proper drainage and

concrete apron in between structure and

track and nearby area at all above

locations so that waste water and soap

solution will drain out immediately to

adjacent main drainage and avoid

adverse effect on sleepers and track. Due

to proper apron and drainage,

accumulated dirt and waste are easily

cleaned and maintained with hygienic

condition.

OLD STRUCTURE OF PLANT

RENOVATED STRUCTURE

OF COACH WASHING

PLANT



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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

the cost.



24.0 PROCESS OF COACH CLEANING AND WASHING IN DIFFERENT

STAGES

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

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

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

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

coach through number of holes provided on water pipelines erected around

in a row.

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

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

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

pressurized soap solution inside the sprinklers to get more bubbles formed

when it strikes with coach surface.

Two sides and roof of

coaches are completely

wetted by low velocity

sprinklers at this stage,

some loose dust & dirt is

washed away from coach

surface and

simultaneously, coach

surface is made uniformly

wet, which help in even

application of soap

solution on coach body.

Due to release of surface tension in

bubbles, dirt particles are loosened

and washed away easily. Flow and

quantity of soap solution can be

controlled and adjusted by operating

spindle nut on sprinkler and both

valves provided on soap solution

line and pneumatic line.



24.4. SOAKING OF SOAP SOLUTION: In this stage, soap solution is

allowed to soak completely for approx.1 minute in normal washing process.

This stage is automatically achieved while rake is moving at 5 Km/h.

through coach washing plant, since stage 3 and stage 5 is kept apart at 30

meter distance. During this stage, soap solution, is chemically reacted with

dirt.

This pressurized spray clean underneath portion of toilet and near by area

which is normally spoiled with wet soil. This process is also helping in

prevention of breeding of cockroaches which generally take place in this

area. Further, it also helps in maintaining hygienic conditions for working

staff, who specially work or attend safety fittings in this portion of a coach.

In this stage, sides of bogie are also cleaned by high pressure water jets

simultaneously.

24.3.RUBBING OF SOAP SOLUTION: This stage is especially incorporated to get

more effective cleaning. In this stage, soap

solution is rubbed and made even

application on both sides of coach by two

vertical nylon brushes one at each side of

coach .This stage comes into action as

soon as sensor at second stage is activated.

23.5.CLEANING OF UNDERNEATH

PORTION OF TOILET: In this stage,

two sensors are provided for

ascertaining the location of underneath

toilet portion between two adjacent

coaches by sensing of last wheel of

first coach and first wheel of second

coach. As soon as these sensors are

activated in above situation,

pressurized water mixed with

disinfectant and phenol, sprayed from

bottom through four nozzles which are

provided between two rails.



24.6. MOISTENING OF SOAP SOLUTION: In this stage, moistening of

partially dried soap solution is carried out by sprinkling of very low-

pressure water through number of nozzles provided on a water pipe line.

Hence soap solution applied on roof and sides of coach become wet before

rubbing by horizontal and vertical brushes.

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hhaannddllee,, ssppaaccee nneeaarr ttoo ddeessttiinnaattiioonn

bbooaarrdd,, ttuurrnn uunnddeerr aanndd rrooooff ppoorrttiioonn..

EEaarrlliieerr,, tthheessee aarreeaa ccoouulldd nnoott bbee

ppoossssiibbllee ttoo cclleeaann bbyy oolldd ccooaacchh

wwaasshhiinngg ppllaanntt.. TThheessee bbrruusshheess aarree aallssoo

hheellppiinngg iinn rreemmoovviinngg ooff rreesseerrvvaattiioonn

cchhaarrtt ppaasstteedd oonn aa ccooaacchh..

24.7.COACH CLEANING BY HORIZONTAL AND VERTICAL BRUSHES:

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

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

ssttrruuccttuurree..



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

completely wet hence it require mopping. Two vertical brushes with

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

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

pass through these brushes.

This stage is specially effective for

cleaning of AC glass windows where

small water drops are always sticking

and staining glass giving discomfort to

passengers when they are looking

outside through such windows. These

brushes are also used for buffing of

coaches to get shining by rotating it in

dried condition when rake is moved

from pit-line after examination. Since,

requirement of soap solution is less for

external cleaning of rake by this washing

plant. Cost incurred in normal external

cleaning of a rake of 21 coaches is Rs.

400 approximately. This cost includes

cost of material like soap solution and

cotton ropes (which are normally

replaced once in a month) and cost of

electrical power.

24.8. AFTER WASH: In this

stage, washing of roof and sides

of coaches are carried out after

rubbing of soap solution by

vertical and horizontal brushes.

High-pressure water is sprayed on

coach surface through eight high-

pressure sprinklers to wash coach

completely. In this stage, washing

of roof takes place just before

washing of sides by spraying of

water through high velocity

sprinklers provided at top of

structure. This arrangement is

made purposely to allow dirty

water after roof washing to flow

down on both sides of coaches

before washing of sides of

coaches.



25.0 Water Recycling treatment plant :

The water recycling in Railway coaching depots may help in conservation of water.

Details of components of water recycling plant for 100 m3 /

/hr. are given below:-

A. Waste water collection sump:

Qty.- One No.

Size – underground 2.5M x 2.5 M x 4M

B. Booster pumps:

Qty.- Three units

Type- Horizontal Mono block type electrically operated with 3-phase 440 V AC.

C. Online Coagulation dosing plant:

Qty.- One unit

Type- Online operation for dosing of liquefied coagulant in water before primary

settling tank.

D. Online chlorination plant:

Qty.- Two units

Type- Online operation for dosing of liquid chlorine solution, i.e. Sodium

Hypochlorite solution at pre and post filtration stages.

E. Water settling tank:

Qty.- Two chambers

Type- Over ground sump type. Both the chambers are inter-connected on top for

trickling of water for easy settling of suspended impurities and subsequent

removal by double filtration.

F. Pressure filtration plant:

Qty.- Two units

Type- M.S. vertical down-flow model with dish ended M.S. shell and at bottom

four legs.

25.1 Process of Water Recycling:

1. Waste water is collected in a sump received from washing line drainage.

2. Water is feed to settling tank by submersible pump.

3. Before feeding to settling tank water is coagulated with the help of pre-

chlorination plant.

4. Time required for settling of impurities in settling tank is 3 hrs.

5. Supply of water for re-using in washing of trains is supplied through two

mono-block pumps via two vertical filtration plants connected in series.(Pre-

filtration and Post-filtration plant).

6. Chlorine is added in suitable amount after filtration for post-chlorination.

7. After post-chlorination, water is supplied for washing of trains in

washing line.



Fig.25(a) Systematic Diagram of Installation of Water Recycling Plant.

Fig. 25 (b) Execution plan for water recycling plant.



26.0 INTERNAL COACH CLEANING MACHINE

This machine is departmentally designed and developed for cleaning of

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

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

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

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

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

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

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

side wall by using various type of brushes.

FLOOR CLEANING BERTH CLEANING

WINDOW GLASS CLEANING TOILET CLEANING



27.0 TRANSPORTATION CODES FOR LHB COACHES

[ Ref: APPENDIX ‘D’ of Maintenance manual for LHB ]

Sr.No TYPE OF LHB COACH CODE

1 AC FIRST CLASS SLEEPER- (EOG) LWFAC

2 AC FIRST CLASS SLEEPER- (SG) LWGFAC

3 AC SECOND CLASS SLEEPER- (EOG) LWACCW

4 AC SECOND CLASS SLEEPER- (SG) LWGACCW

5 AC THREE TIER CLASS SLEEPER- (EOG) LWACCN

6 AC THREE TIER CLASS SLEEPER- LACCN (SG) LWGACCN

7 AC DOUBLE DECKER AC CHAIR CAR (EOG) ACCC DOUBLE DECKER

8 AC HOT BUFFET CAR LWCBAC

9 LHB GS EOG coach fitted with the new inner spring design of

secondary suspension (LW05127) with a combination of existing

LG05101 outer spring (Shalimar coach secondary outer spring) and

Rubber spring with 36 mm shim.

LS4

10 NON AC SECOND CLASS THREE TIER–(SG) LWGSCN

11 NON AC- LUGGAGE CUM GUARD VAN(SG) LGSLR

12 AC CHAIR CAR EXECUTIVE CLASS LWFCZAC

13 AC CHAIR CAR LWSCZ AC

14 GENERATOR CUM LUGGAGE& BRAKE VAN LWLRRM

15 EOG NON AC HOT BUFFER LHB COACHES LWCB

16 EOG AC FIRST CLASS CUM AC TWO TIRE LHB COACH LWFCACCW

17 II class non-AC EOG LHB variant in BG coach fitted with

modified suspension on FIAT bogie with suspension to Drawing

No. LG 90018 with 32 mm shims without 2 under slung water tanks

of 685 Lt capacity, luggage rack shifted upward by 440 mm.

LS 2`

18 II class non-AC EOG LHB variant in BG coach fitted with

modified suspension on FIAT bogie with suspension to Drawing

No. LG 90019 with 32 mm shims without 2 under slung water tanks

of 685 Lt capacity, luggage rack shifted upward by 440 mm.

LS 3

19. EOG non AC chair car LHB variant coaches fitted with FIAT bogie

with 16.25 t axle load

LWSCZ



Suggestions given by Zonal Railways for Coaching Depots during

seminar on 21.07.2014

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

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

catwalk.

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

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

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

be developed for better and safe maintenance.

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

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

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

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

should also be provided on this switch board.

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

having holding more than 250 coaches.

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

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

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

platforms.

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

etc. Specifications may be collected from them.

Suggestions given by Zonal Railways for Coaching Depots during

seminar on 20.07.2015

Catwalk: Catwalk is necessary

Covered shed for Pit line: Covered shed should not be provided for maintenance pit line.

Maintenance Pit line: Length of pit line should be increased to 675 meters for 28 LHB coaches.

Linen Room: Size of linen room should be increased to 10 X 10 M

Conference hall: Size should be increased to 10 X 10 M or 5 X 15 M

Air Compressor with air dryer: Air dryer should also be provided with compressor.

Sewing Machines: Nos. to be increased to 2

Pipe bending machine: 01 Pipe bending machine should be included in the list for SS air brake

pipes of LHB coaches.

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