Quality Audit report Of Coaching Depot Bhubaneshwar, ECo Rly _[19-2012]_Coaching...Quality Audit...

Quality Audit report

Of

Coaching Depot

Bhubaneshwar, ECo Rly

Report no. 19/2012

APRIL 2012

(Audit is done by CRSE, NCR)

of 29 Coaching depot – BBS, E.Co Rly April 2012

Quality audit of Report Coaching Depot, BBS, E.Co Railway

1.0 Introduction

Railway Board vide letter no. 2012/M(W)814/5 dated 20.3.12 has instructed

zonal Railways to conduct Quality audit of coaching depots and workshops of

other Railways. Accordingly NC Railway has been entrusted to do the quality

audit of BBS coaching depot of ECo Railway.

1.1) Audit team - Shri B M Agrawal , CRSE/NCR, Shri A K Dwivedi, Sr DME

/C&W/ALD, Shri Amresh Singh, SSE/C&W/ALD, Shri Vinod Navik,

SSE/C&W/ALD and Sri S K Garg SSE/C&W/ALD

1.2) Dates of audit - 05.04.12-06.04.12 and11.04.12.

1.3) Escorting Officers - Shri Manoj Kumar Sr.DME/C&W/KUR , Shri D P Mishra

CDO/BBS, Shri P S Tomar, ADME/C&W/BBS, Shri P K Sahu

SSE/C&W/BBS

1.4) Scope of audit - Sick lines, Washing lines, Platforms C&W office, Rolling in

point, Linen room, Store rooms and CDO/BBS office.

2.0 Brief about visit

Coaching Depot of Bhubaneswar is situated in a centrally located place in the temple city of Bhubaneswar, just 1/2 km away from Bhubaneswar Railway station. Main infrastructure comprises –

Integrated pit lines - Two 26 coach length & one 21 coach length; Dry pit – one 16 coach length; Washing pit – one 18 coach length; Sick line/IOH shed – Two lines of 4 coach capacity. Trains maintained in the depot are – PM trains 20 (Rakes 24), SM trains 02 (Rakes 5).

During the audit, infrastructure available in the coaching depot, system of working, process and procedures adopted, record keeping & monitoring system and supervision, planning etc were studied. The escorting officers and supervisors were present throughout the audit.

3.0 Strengths

3.1 The safety maintenance of various gas pipe lines fittings and Round trip safe-to- run certification of the Pantry cars are being carried out by Depot through outsourcing.


3.2 The maintenance of CDTS has recently been outsourced and being carried

out by M/s Banka Enterprises, Hyderabad. The scope of the work includes

supply of material, fitment & schedule attention of the system . The firm is

attending to both ‘Vibhu’ and ‘Aikon’ make CDTS. CDTS functionality was

reported to be over 95% now.

3.3 VESDA (Automatic Smoke and Fire detection with alarm system) is provided in

18 LHB coaches by RDSO and being monitored for its effectiveness.

3.4 Air dryers have been provided with compressors at the washing line, which

were found to be functional.

3.5 Stores depot has been designed to have single exit/entry of the material

facilitating closer watch on material movement.

3.6 24 Hrs Water supply in washing line with adequate discharge rate for watering

and cleaning attention of coaching stock is being ensured.

3.8 Adequate illumination in washing line with portal lights & path way lights under

the catwalk platforms have been provided. The depot has recently installed 110

Volt DC tube light fittings inside the pit on experimental basis to avoid theft of

fittings which are currently working.

4.0 Weaknesses

4.1 Adequate gang strength and proper supervision at primary end is not being maintained due to acute shortage of man power. (Supervisors–22, Artisan staff –264).

4.2 During last 5 years the coach holding of the depot has gone up substantially from 205 to 427 without adequate provision of resources in terms of man power, infrastructure, M&P etc. Large no. of coach maintenance contract needs proper supervision at supervisory and officers level for their successful execution, which is lacking due to crisis of supervisors.

4.3 Due to less lie-over period and pit line constraint TN 18496 (BBS-RMM) & TN 78420 (DMU) are not being given 6 hrs maintenance time on one day (Friday).

4.4 Scotch blocks with locking arrangement are not provided for safety of the staff working on washing/cleaning job to prevent movement/disturbance in the activity, only protected with board/signal.

4.5 DRS card and DDR are not being maintained due to shortage of man power.

4.6 Coach maintenance History card is not being maintained.


4.7 Detachment of Pantry cars from rakes once a month (within reasonable tolerance) is not being done to facilitate complete vacation and intensive cleaning for thorough pest / rodent control treatment.

4.8 Adequate sick line facility is not available, therefore coaches are being sent to

MCSW for IOH.

4.9 Deployment of fewer no. M&P vis-a-vis requirements for proper cleaning of

coaches on washing lines is affecting cleaning of coaches.


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 Observation

1. Periodicity of periodic overhauls (POH) in designated workshops is being followed.

103 of Chg. Manual Table 1.1 and correction slip 5 issued in 2008 RB letter no. 2007/M ( C)/141/1 dtd 26.09.08

Coach holding - 427 Overdue POH - 06

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

It is followed as per BG Coaching Manual

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

Coach holding - 427 Overdue Sch A - Nil

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

Coach holding - 427 Overdue Sch B - Nil

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 - 427 Overdue IOH - Nil

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 The coaches, which are due for IOH/“C” sch., are sent to base depot.

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

Being followed.

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

107 a (i) of Chg. Manual

It is done as per Chg. Manual. PM trains – 20 consisting of 24 rakes



SM trains – 02 consisting of 05 rakes. (List enclosed)

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

107 b of Chg. Manual

It is done at Platforms of BBS station. Besides the terminating trains, the HWH-YPR Duronto Exp. (hybrid type) is also attended as per RB guidelines.

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

107 (b)(i)(a) of Chg.Manual Suitable site has been nominated at Platform.

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

107 (b)(i)(d) of Chg.Manual 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 Only terminating trains and HWH-YPR Duronto Exp. is attended.

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 It is done and proper record is being maintained.

9. Revised maintenance pattern for coaching trains circulated vide Railway Board’s letter No.95/M(C)/141/1 dt.31.01.07

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

9.1 While permitting introduction of round trip primary pattern of maintenance on coaching trains, approved mandatory condition at primary end and other end as detailed in Railway Board’s letter No.95/M(C)/141/1 dt.31.01.07 is followed.

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

It is followed. (Round trip BPC provided in 13 PM trains)

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- Yes it is done.

ii) Brake blocks should be changed in bogie sets only


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

-do- Depot is trying its level best to turn out as ‘Zero-Missing-Fitting’ rake, however few deficiencies e.g. Magazine Holders, Snack tables, looking mirrors in SCN and missing slats in luggage rakes of GS coaches were noticed.

iv) Intensive cleaning of coach toilets and lavatory. -do- Yes it is done (Mechanised cleaning contract is available)

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

-do- Due to less lie-over period and pit line constraint following two trains could not be given 6 hrs. maintenance time on one day (Friday) only. i) Tr. No.18496 (BBS-RMM)



ii) Tr. No. 78420 (DMU) (Pit Occupation chart enclosed)

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

-do- It is available. (02 nos. Integrated Pit Lines are available with Catwalk and one Maintenance line without catwalk, also one washing line without pit but catwalk is available)

vii) Adequate gang strength with proper supervision

-do- Due to acute shortage of man power adequate gang strength is not available. (Supervisors – 22, Artisan staff – 264)

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


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

-do- It is available.

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- Pertaining to KUR Division.

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

As per depot rake link and Pit Occupation chart maintenance is being done.

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 It is followed on contract basis.

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 Recommended solutions and cleaning agents are being used as mentioned below. i) All Klean, ii) Super Lime Away Plus iii) Super Klean iv) Hand Wash v) F-400 vi) N.C. Thinner vii) Room Freshner All of Scheveran make.

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 It is ensured by protecting with proper board, but scotch blocks with locking arrangement was not provided.

12.3 External cleaning /washing: Check that guidelines as detailed in CAMTECH manual are being followed.

109 (b) of Chg. Manual Though it is largely done, yet improvement in terms of cleaning with high pressure jets on both sides needed.



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

109 (c) of Chg. Manual It is followed.

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 It is followed.

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

109(e) of Chg. Manual It is followed.

12.7 Cleaning of buffers and screw couplings 109(f) of Chg. Manual Yes it is followed.

(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 Yes it is followed.

(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 It is followed.

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 Not any 24 coach train is maintained at this depot.

(i) 24 coach length fully equipped pit line. 110(a)(i) of Chg. Manual N.A.

(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 N.A.

(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 N.A.

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

110(a)(iv) of Chg. Manual N.A.

13.2 Coach Design related requirements 110(b) of Chg. Manual N.A.

(i) Air brake with twin pipe graduated release

system

110(b)(i) of Chg. Manual N.A.

(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 N.A.

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 N.A.

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

110(c)(ii) of Chg.Manual N.A.

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

110(c)(iii) of Chg.Manual N.A.

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 N.A.

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

110(c)(v) of Chg.Manual N.A.



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

110(c)(vi) of Chg.Manual N.A.

vii) Provision of audio visual alarm system on the locomotive

110(c)(vii) of Chg.Manual N.A.

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

111(f)(i) of Chg.Manual As per Bureau of Indian Standard, refilling is to be done in every 03 years, but as per Tender schedule it is being done in 18 months.

14.1 Provision of DCP type fire extinguisher in a rake should be in accordance with guidelines circulated vide letter no. 95/Sec (spl)/75/1 dtd 30.05.97

Coach type Nos of FE’s

Each Break Van 2 nos

Each AC coach 2 nos

Each Pantry car 4 nos

Each Generator van

2 nos

RB’s letter no. 95/Sec (spl)/75/1 dtd 30.05.97

DCP type Fire extinguishers are provided as per guide lines. Each SLR: - 02 Nos. Each AC: - 02 Nos. Each WCB:- 04 Nos. Each Power Car:- 02 Nos

15. Similarly, other brake van equipment, which Mechanical Train Examining staff is responsible to supply, should be provided according to the instructions of each Railway. Portable control telephones, portable train lighting equipments, portable fire extinguisher, wooden wedges/skids and stretcher are to be provided.

111(g)(i) of Chg.Manual Only Fire Extinguishers and Wooden wedges are supplied through Mechanical side as desired.

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 i) In the depot the filling of all the water tanks of the coaches are ensured. ii) Being BBS is the nominated CTS point, the watering and CTS activities has been outsourced. Total 21 trains are attended for CTS including watering and 18 trains are attended for watering only at BBS.

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 DRS is not being maintained due to acute shortage of man power.

(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 Due to acute shortage of man power it can not be carried out.

18. Coach Maintenance History Card 111(k)(i) of Coach maintenance History card is not being maintained. It is under process.



(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 N.A.

(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 N.A.

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 It is followed.

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

113(b) of Chg. Manual It is 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 It is 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 It is followed.

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

113 (e) of Chg. Manual

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

i) Shatabdi coach is not available. ii) The Rajdhani Coaches are of LHB type. iii) The Duronto Exp. coaches are checked in prescribed period.

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

113(e)(ii) of Chg. Manual It is being done.

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 It is being done.

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 It is being done.

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

iii) Door lock handles 113(f)(iii) of Chg.Manual It is being done.

iv) Tower bolts 113(f)(iv) of Chg.Manual It is being done.

v) Window shutters should neither be tight nor loose

113(f)(v) of Chg.Manual It is being done.

vi) Window shutter safety catches 113(f)(vi) of Chg.Manual It is being done.

vii) Window frame 113(f)(vii) of Chg.Manual It is being done.

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

113(f)(viii) of Chg.Manual It is being done.

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

113(f)(x) of Chg.Manual It is being done.

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 It is being done.

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

113(f)(xii) of Chg.Manual Deficiencies are largely made good during maintenance

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 A Trip Schedule Register is maintained for the same.

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 It is being done.

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

114(b) of Chg.Manual It is being done.

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

114(c) of Chg.Manual It is 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 It is being done.

ii. The specified items of work should be attended.

115(b) of It is being done.

iii. Brake system maintenance

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

Chg.Manual It is 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 It is being done.

b. Painting of lavatories from inside. 115(b)(iii) of Chg.Manual It is being done.

c. Thorough inspection and repairs of brake gear components.

115(b)(iv) of Chg.Manual It is being done.

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

115(b)(v) of Chg. Manual It is being done.

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

115(b)(vi) of Chg. Manual It is being done.

22. IOH attention

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

22.1 Periodicity of IOH attention:

Coach Category

Periodicity

New coach at interval of 12 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

i) The coaches having 24 months POH periodicity (new coach) are attended for IOH at the depot. ii) The coaches having 18 months POH periodicity are attended for IOH at Workshop and Coaching Depot, PUI. iii) The coaches having 12 months and passenger coaches having 18 months POH periodicity are attended for “C” sch. at the depot.

iv) Rajdhani coaches (LHB type) of 36 months POH periodicity are sent to JUDW/LLHM for IOH.

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

It is done.

22.3 Brake system : ‘C’ schedule maintenance

(IOH) as per para 426 of air brake chapter. 117(a)(i) of Chg. Manual It is done.

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

117(a)(vii) of Chg. Manual It is done.

22.5 Other assemblies maintenance

All items of Schedule `B' 117(a)(i) of Chg. Manual It is done.

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 It is done.

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

117(a)(iii) of Chg. Manual It is done.

22.8 Polishing of the polished surfaces. 117(a)(iv) of Chg. Manual It is done.

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 It is done.



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 It is done.

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

117(a)(vii) of Chg. Manual It is done.

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 It is done.

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 It is done.

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

117(a)(x) of Chg.Manual It is done.

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 Engineers (C&W) are aware of this.

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 Yes, it is done

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 It is done.

III) A register should be maintained of the primary maintenance coaches on the subject. Record of Schedule A, B and IOH attention are maintained in standard format and records are maintained.

117(e)(iii) of Chg. Manual It is done.

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 It is followed

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

118(c) of Chg. Manual It is followed.

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.

i) Yes daily requirement of Bed roll set – 3356 approx. ii) Distribution of Linen kits in trains is being done through Electrical Deptt. except Tr. No. 22811/12 & 22823/24, which is being done by Mechanical Deptt.



iii) The Tr. No. 18463/64 is being managed by IRCTC.

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

It is done.

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.

It is being done.

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

It is being done. Total 41 inspections are carried out. from Jun,11 to Mar,12 and Rs. 65,000/- penalty imposed.

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

It is available.

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

It is followed.

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

Committee nominated.

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

It is adhered to.

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

Yes, total nos. of Passenger complaints received during Apr, 11 to Feb, 12 are 26. Penalty imposed is Rs. 52,000/-

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

Yes, obtained.

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

A contract was awarded to M/s PCI Ltd. for one year from 16.11.09 to 15.11.2010 and extended for 17 months up to 15.04.2012.

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

All coaches of the trains are covered in the contract.

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.

Minimum frequency for carrying out pest & rodent control treatment is once in a month for all types of coaches.

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

Cockroach Treatment – i) Pest seal (500 ml. for AC, 1500 ml. for PC, 1000 ml. for NAC. ii) Delta Methrine – ( 10 ml. for AC, 20 ml. for PC, 10 ml. for NAC)



iii) I.C. Gel – (5 gm for AC & PC) Rodent treatment – i) Roban cake – 0.5 kg for all types of coaches. ii) Glue board – As per requirement.

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.

Rodent treatment – Monthly twice in all coaches.

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

It is 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

No fumigation is done.

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

It is followed.

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

It is provided.

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

Detachment of Pantry cars is not done, but complete vacation is ensured. Intensive cleaning for thorough pest / rodent control treatment.

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

After treatment by counting.

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

During Apr, 2011 to Dec 2011 total 42 Nos. passenger complaints have been received against which penalty of Rs. 42,000/- has been imposed on the firm.

25. Passenger amenities provided in various

types of coaches as specified

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

It is provided.

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

One standard and other two non-standard.

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.

It is checked.

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

It is followed.


S.No. Item Clause Observation (N)/960/1/Vol I dated 15/18.3.99)

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

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

It is followed.

a) Shattered Rim It is being done.

b) Spread Rim It is being done.

c) Shelled Tread It is being done.

d) Thermal Cracks It is being done.

e) Heat checks It is being done.

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.

It is maintained.

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

It is followed.

27.2 Roller Bearing Axle Boxes Para 1009 b of Chg manual

i) A coach should invariably be detached from service for the following defects i) Hot axle box ii) Damaged axle box iii) Damaged front or rear cover iv) Seized roller bearing v) Coach involved in accident, derailment, fire, flood etc.

It is followed

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

It is 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.

It is followed

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

It is followed

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

It is followed



ii) If temperature is found above 800 C, the

affected coach will be detached.

It is followed

27.4 Minimum permissible wheel diameter in ICH design BG coaches.

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

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

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.

It is 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

Modified brake hangers are being provided from workshop.

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

It is followed

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

It is 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

It is followed and super check is done.

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

RDSO spec and STR It is provided from workshop.

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

It is provided from workshop. Maximum efforts are being done for providing all items during maintenance subject to availability of items/man

29.4 Additional amenities / facilities in GSCN type of coaches are provided as under:

Snack table in each bay. Mirrors in each bay Magazine holders on partition wall Bottle and tumbler holder

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

It is provided from workshop. Maximum efforts are being done for providing all items during maintenance subject to availability of items/man

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

It is followed

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.


Rolling-in & out examination of HWH-YPR Exp. is done for both up & down trains as it has operational halt at BBS.

iii) Short distance Duronto with only only AC / Non AC chair car may be permitted to run on the extant pattern for Shatabdi trains with a terminal attention at other end on platform / stabling line. A minimum 2 hrs may be planned at the non primary end to enable thorough attention to cleanliness, hygiene and passenger amenities at other end.


N.A.

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

It is followed

29.6 Attention of air springs ED/Carrg/RDSO’s letter no. MC/CB/MM dtd 09.09.2009 & Maintenance manual of air spring

Procedure for rolling – in examination: As train passes the nominated point, C&W staff

It is followed


S.No. Item Clause Observation 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.

for mainline ICF bogie coaches RDSO/2009/CG/CMI-01, Sep’09

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.

Yes attached in Annexure-A

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

Yes, attached in annexure-B

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.

Yes, attached in annexure-B

29.8 Facilities for pit line and sick line attention CAMTECH Maintenance Manual

for BG Coaches of ICF design,

1st correction slip– CAMTECH/2002/M/C/ CMM/1.0/CS-01(07.2006)

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

Yes, available

30 Passenger satisfaction

30.1 OBHS & escorting of trains

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

The depot has the provision of OBHS in some nominated trains.

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

Two nos. i.e. BBS-NDLS Rajdhani & Duronto Exp.

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

12 nos. including Rajdhani & Duronto Exp.

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

All the 12 nos. nominated trains have been provided with OBHS through contract only.

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

It is maintained.

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.

The depot has the system to get the Feedbacks from passengers.

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

The depot has the system to analyse passenger complaints and accordingly corrective action is taken.

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.

i) Portable type High pressure Jet Machine ii) Portable type Single Disc Mini scrubber & Scrubber rider iii) Portable type Wet & Dry Vacuum Cleaner



iv) Hand held electric driven scrubber. Average 11 rakes (182 coaches) are cleaned per day.

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

Outsourcing of the work is in process.

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

It is followed. At a interval of 30 days

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

Blankets are cleaned in two months as per Contract Agreement. In next contract the period will be one month.

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.

It is maintained.

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

It is being done.

c) Sustainable garbage collection and disposal system

As per norms.

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

It is done.

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

It is not done.

f) Monitoring the functioning of OBHS and CTS scheme.

It is being monitored.

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.

The trains under “OYTS” are being maintained.

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.

It is done.

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

Under process.

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

Yes it is done.

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

It is followed.

31.2 Attention to following components are being given as per Alsthom manual guidelines and guidelines circulated by RDSO. Phonic wheel / speed sensor.

Alsthom manual and OEM manuals

Attention is being given. i) AMC of the WSP system for


S.No. Item Clause Observation Dump valve Earthing device. Control arm Dampers

Primary vertical dampers. Secondary vertical dampers Yaw damper. Secondary lateral damper

Primary and secondary springs Disc brake attention CDTS (Controlled discharge toilet

system)

M/s Knorr & Bremse already awarded and for M/s Faiveley Transport India Ltd. is under finalisation, which includes Phonic/speed sensor, Dump Valve etc. The maintenance of CDTS has been outsourced.

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 It is being done in D-1 Schedule.

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 It is being done in D-1 Schedule.

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 It is followed.

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

It is being done.

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

It is being followed.

vii) Presently the refurbishing/overhauling of LHB bearing is being done at an interval of 1.2 million km. To ensure attention of CTRB’s as well as UST of axle, depot should have proper identification of wheels sets. In case wheel sets are interchanged then traceability of wheel sets and timely attention of wheel sets exist in the depot.

It is not available in the depot.

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

Adequate spares of wheels 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.

It is followed.

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

It is done.

xi) Drain holes of control arm should be regularly It is done.


S.No. Item Clause Observation cleaned to prevent its choking.

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

It is done.

31.4 Phonic wheel/Speed censor OEM guidelines

i) M8 size screw to IS 1367 Pt.III class 10.9 along with spring washer to the IS 3063 type-B should be used for securing phonic wheel. LOCTITE 243 or equivalent glue should be used to ensure rigid connection between internal and external thread. The Phonic Wheel screws should be tightened with 21N-m torque.

A special drive was taken and all the non-standard screws were replaced with RDSO specified screw.

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.

It is being done during D-2 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.

It will be procured from OEMs through AMC.

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

It will be followed.

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

OEM guidelines It is being done during D-1 schedule.

31.6 Earthing Device OEM guidelines

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

Outsourcing of maintenance of Earthing device is under process.

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

.Corrective action will be taken

after contract

Junction box in broken/damaged condition.

.Corrective action will be taken

after contract

31.7 Disc brake attention: OEM guidelines

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

It is done.

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

It is ensured.

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

Presently it is being done in-house, LOA has been issued for AMC.

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

It is 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

It is maintained.


Annexure - I

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

1st correction slip– CAMTECH/2002/M/C/CMM/1.0/CS-01(07.2006)

Classification of depots

Classification No. of coaches based

Minor Depot Below 100

Medium Depot 100 to 250

Major Depot Above 250

Machinery and Plant

Description Minor

Depot

Medium

Depot

Major

Depot

Observation

U/floor wheel lathe - - 1

Sanctioned vide item no. 455

under RB’s M&P Programme

(PH-41).

Whiting jacks (5 Nos.) - 1 set 1 set 03 sets

EOT crane 20T - - 1 Nil

Coach Shunter - 1 2 Nil

Welding Plant 1 2 4 04 sets

Gas Cutting Equipment 1 2 2 01

Vacuum Exhauster 1 2 2 Nil

Air Compressor 30 cfm 1 2 2 03

Portable Vacuum Testing Equipment - 1 1 Nil

Portable Air Compressor - - 1 02

2T Tram beam hoist 1 1 2 Nil

Sewing machine - 1 1 Nil

Truck 10T - - 1 Nil

Light Coml. Vehicle 1 1 1 Nil

Fork lift truck - - 1 4

Lister truck 1 1 2 1

Car Washer - 1 1 Nil

Portable Trolley Light 2 4 Nil

Cotton waste soaking plant 1 1 1 Nil

Wood cutting saw machine - 1 1 Nil

Hand shearing machine - 1 1 Nil

Portable Furnace 1 1 2 Nil

Centre Lath - - 1 Nil


Description Minor

Depot

Medium

Depot

Major

Depot

Observation

Bogie Manipulator - - 1 Nil

Ultrasonic Testing Apparatus 1 1 1 Nil

Tool post Grinder - 1 1 01

Vacuum Cleaner 1 2 3 01

Pressure Jet Cleaner 1 2 4 01

Tools

a. Pneumatic Hand Tools

i. Grinder 1 1 2 01

ii. Drill 1 1 2 Nil

iii. Chipper / Buster - 1 2 Nil

iv. Riveter - - 1 Nil

b. Electric Power Tools

i. Pop Riveting Gun - 1 1 01

ii. Drill - 1 1 02

iii. Bolt Tightner - - 1 Nil

c. Hand Tools As required Lump sum

d. Test Bench

i. Water Tank Test Rig - 1 1 Nil

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

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

iv. Slack Adjuster Test Bench - 1 1 Nil

v. DV Test Bench - 1 1 Nil

vi. Air brake single coach test rig - 1 1 02

e. Office Equipment

i. Computer system 1 1 1 01

ii. Plain Paper Copier 1 1 2 01

iii. Telefax 1 1 01


Annexure - II

Emergency materials required for platform (C&W) office

Sl. Items Required Observation

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

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

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

4 Draft link complete 2 sets 1 set

5 Equalizing Stay rod with pins ( Non-modif.

& Modif.) 1 set each 1 set each

6 Anchor link with securing studs 1 set 1 set

7 Truss Bar Hanger with Pins & Cotters 2 sets 2 sets

8 Bolster suspension Link (Stirrup Link) with

Pins & Stones 2 sets 2 sets

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

Pins 2 sets 2 sets

10 'O' Ring 2 nos. Nil

11 Grease Servogen 4 kgs. 4 kg

12 Adaptor (BF+FP) for by-passing 2 sets 1 set

13 Angle cock 2 nos. 2 nos.

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

15 M.U. washer 10 nos. 10 nos.

16 Teflon Tape 1 no. 1 no.

17 Portable Air Pressure Gauge 1 no. 1 no.

18 Pressure Gauge BP & FP 2 each 1 each

19 BP & FP Air hose 2 each 2 each

20 Guard Emergency Application Valve 2 nos. Nil

21 Wooden Plug (various sizes) 10 nos. Nil

22 Wooden wedge 4 nos. 2 nos.

23 G.I. wire Adequ. Qt. Available

24 Buffer bolts (20x120 mm.) 8 nos. 4 nos.

25 Push cock 5 nos. 10 nos.

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

27 Slide wrench, Pipe wrench-24'' 2 nos 1 no. (18”)

28 Hydraulic Jacks 2 sets 1 set


Annexure – III

Details regarding coaching depot

Depot name and division: Coaching Depot, Bhubaneswar, Khurda Road Division, E. Co. Railway.

1. Coach Holding

Mail/Expresses coaches with conventional coupling 307

Mail/Expresses coaches with CBC coupling 24 (Hybrid)

Rajdhani/Shatabdi coaches (conv) Nil

LHB coaches (Rajdhani/Duronto) 49 (Rajdhani)

Shatabdi Coaches (conv) Nil

Shatabdi coaches (LHB) Nil

Passenger coaches 32

OCV’s 15

Grand Total 427

2. Maintenance attention of at depot

PM of Mail/Expresses train with secondary attention at other end 06

PM of Mail/Expresses train with round trip attention at other end 13

PM of passenger service with round trip attention at other end 01

Total PM attention at depot: 20

Total SM attention at depot: 02

Total Round trip attention at depot: 02

3. Pit line attention

24 coach pit with catwalk and high pressure water jet

facility/watering facility at per CAMTECH’s guidelines

01 IPL

24 coach pit facility with catwalk 01 IPL

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

be collected)

01 (20 coach length catwalk)

01(16 coach length without catwalk)

Stabling line for round trip attention and stabling of rakes:

Stabling line with 24 coach length facility

Stabling line with less than 24 coach facility

Nil

02

05

Compressed air with reservoir and Air dryer/moisture trap facility

with test rig (RTR)

03 Compressor with 02 nos.

dryer

Facility for welding at Yard attention Available

Night maintenance facility with overhead/pit light as per

CAMTECH’s guidelines

02 nos. IPL available with

Portal light including Pit light

in IPL-1 (160 nos.) & IPL -3A

(60 nos.)

4. Sick line facility

Coach lifting facility with overhead crane Nil

Coach lifting facility with JMP jack/hydraulic jack 03 sets JMP Jacks for coach

lifting

Total coach accommodation

With pit attention Without pit attention

02 (Mech.) & 02 (Elect.)

Nil

Facility for compressed air with test rig (SCTR) 02 nos. available

Availability of hydrant water for overhead tank attention Not available

Welding facility Available


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

night) as per CAMTECH’s guidelines – Available.

6. Availability of staff for coaching maintenance as per Yard stick –Adequate Staff not available.

7. Training status of supervisor and staff – Maximum overdue due to insufficient staff and supervisors.

8. Availability of critical/ safety stores and storage system - available.

9. Availability of coaches as per rake link with maintenance spare - available.

10. Bottlenecks / limitations of system / depot –

i) During last 5 years the coach holding of the depot has gone up substantially from 205 to 427

without augmentation in resources in terms of man power, infrastructure, M&P.

ii) Outsourcing to the extent of 100% of certain coach maintenance activities e.g. mechanised

cleaning of coaches on washing line with no fallback arrangement in contingency has limited

management’s ability to enforce the contract in-toto/ discipline the erring contractor.

11. Safety performance record – All the safety drives are conducted and reports submitted

accordingly.

12. Performance of critical spare – List enclosed.


Cleaning of chequered plate

under Mechanized cleaning Mechanized cleaning of rake at pit line

Cleaning of window shutter with Brush banister


Technical instructions displayed at sick line to enhance technical knowledge of staff

Porter Light Illumination at Washing Line


Clean Doorways

Quality Audit report Of Coaching Depot Bhubaneshwar, ECo Rly _[19-2012]_Coaching...Quality Audit...

Documents

Transcript of Quality Audit report Of Coaching Depot Bhubaneshwar, ECo Rly _[19-2012]_Coaching...Quality Audit...