10. Maintenance Depot 12.02.2016 finalThe Maintenance facilities for BHU to BHEL Corridor and Benia...

Detailed Project Report for Rail Based Mass Transit System in Varanasi

Final Report CHAPTER 10: MAINTENANCE DEPOT

February, 2016 0‐1

1100.. MMAAIINNTTEENNAANNCCEE DDEEPPOOTT

10.1 INTRODUCTION

The Maintenance facilities for BHU to BHEL Corridor and Benia Bagh to Sarnath

Corridor of Varanasi MRTS are proposed to be provided at Ganeshpur Depot

near BHEL for about 56 rakes of 3 car. Since, track connectivity between the

two corridors is proposed at Beniabagh, one major depot near BHEL i.e.

Ganeshpur Depot is planned to cater to the maintenance requirements of the

corridors of Varanasi MRTS. The depots will have infrastructure to maintain the

rakes with necessary facilities viz stabling lines, scheduled inspection lines,

workshop for overhaul, unscheduled maintenance including major repairs,

wheel profiling, heavy interior/under frame/roof cleaning etc. for the rolling

stock operational on the corridor as well as maintenance facilities for Civil –

track, buildings, water supply; Electrical – Traction, E&M; Signalling &

Telecomm.; Automatic Fare Collection etc.

In broad terms, based on the planned rolling stock requirements, this chapter

covers the conceptual design of the following aspects of the Depots.

Conceptual design and layout of servicing shed and workshop to provide

maintenance facilities and stabling facilities for Rolling Stock.

Operational and functional safety requirements.

Ancillary buildings for other maintenance facilities.

Electrical & mechanical services, power supply and distribution system.

Water supplies, drainage & sewerage.

The details of the depot are provided on conceptual design basis and will work

as a guideline for detailed design later.

10.2 MAINTENANCE PHILOSOPHY

The outline of the maintenance philosophy followed would be as below:

Typical Maintenance schedules being followed by Bangalore Metro have

been considered for determining the requirement of lines in depot.

Unit replacement and to get essential repairs to major equipments done

by the OEMs.



February, 2016 Page 10‐2

Automation with state‐of‐the‐art machinery to ensure quality and

reliability. Labour intensive procedures will be kept to the minimum.

Maintenance staff shall be given special training to develop high‐level

skills in their trade to ensure quality and productivity in their

performance.

Adequate facilities for the stabling have been provided at the depot.

To maintain high degree of cleanliness, Automatic washing plant has

been proposed for cleaning of rakes.

10.3 PLANNING OF MAINTENANCE FACILITIES SETUP

The Rolling Stock requirements in different horizon years for the proposed

corridors are indicated in Table 10.1:

TABLE 10.1: RAKE REQUIREMENT FOR DIFFERENT HORIZON YEARS

Corridor Year 2023 2031 2041 Design

BHU to BHEL

Corridor

(19.4 km)

Headway (seconds) 276 228 174 144

No. of Cars/Train 3 3 3 3

Rakes Required 21 24 32 38

Cars Required 63 72 96 114

Beniabagh

to Sarnath

(9.9 km)

Headway (seconds) 360 258 228 192

No. of Cars/Train 3 3 3 3

Rakes Required 10 13 15 18

Cars Required 30 39 45 54

All the systems and infrastructure on the proposed corridors has been

conceptualized considering 3 car trains operating at 144 seconds headway for

BHU to BHEL Corridor and 192 seconds headway for Beniabagh to Sarnath

corridor.

10.4 ROLLING STOCK MAINTENANCE NEEDS

10.4.1 Maintenance schedule

Servicing requirements shall be determined from the Rolling Stock

manufacturer. Depending upon manufacturer's requirements, servicing

facilities may be provided to include the ability to carry out the inspection,

maintenance, overhaul and repair of the rolling stock fleet, including the

following components:




Body;

Bogies;

Wheels (Re‐discing / re‐axling is planned at workshop only);

Traction motors;

Electrical components;

Electronics; PA/ PIS

Mechanical components;

Batteries;

Rolling stock air conditioning;

Brake modules;

Vehicle doors, windows and internal fittings.

The modern, fully equipped facilities are to be provided that meet these

requirements efficiently and in full. In meeting these requirements, it shall be

assumed that the average daily distance travelled by each rolling stock unit is

approximately 300 km. The following maintenance schedule has been followed

for the conceptual design:

TABLE 10.2: PROPOSED MAINTENANCE SCHEDULE

Type of Schedule

Interval Work content Locations

Daily Daily Check on the train condition and

function at every daily service

completion. Internal cleaning /

mopping of floor and walls with

vacuum cleaner.

Stabling

Lines

A Service

Check

5,000 Km

(approx.

15 days)

Detailed inspection and testing of

sub ‐systems, under frame,

replacement/ topping up of oils &

lubricants.

Inspection

Bays

B Service

Check

15,000 Km

(approx.

45 days)

Detailed inspection of ‘A’ type tasks

plus items at multiples of 15,000 Km

(‘B’ type tasks)

Inspection

Bays

Intermediate

Overhaul

(IOH)

420,000

Km

(approx.

3.5 years)

Check and testing of all sub‐

assemblies (Electrical + Mechanical).

Overhaul of pneumatic valves,

Compressor. Condition based

Workshop




Type of Schedule

Interval Work content Locations

maintenance of sub‐systems to

bring them to original condition.

Replacement of parts and

rectification, trial run.

Periodical

Overhaul

(POH)

840,000

Km

(approx.

7 years)

Dismantling of all sub‐assemblies,

bogies suspension system, traction

motor, gear, control equipment, air‐

conditioning units etc. Overhauling

to bring them to original condition.

Checking repair and replacement as

necessary. Inspection and trial.

Workshop

Heavy

Repairs

‐ Changing of heavy item such as

bogies, traction motor, axles, gear

cases & axle boxes etc.

Workshop

The above Schedule may need slight revision based on the actual earned

kilometers per train and the specific maintenance requirements of Rolling

Stock finally procured.

10.4.2 Washing needs of Rolling Stock

The Metro trains are maintained to a high degree of cleanliness and therefore

needs the maintenance schedule as mentioned in Table 10.3.

TABLE 10.3: SCHEDULE OF CLEANING

S.N. Kind of Inspection Maint. Cycle Time Maintenance Place

1. Outside Cleaning (wet washing on automatic washing plant)

3 Days 10 mins

Automatic washing plantof Depot Single Pass

2.

Outside heavy Cleaning (wet washing on automatic washing plant and Front Face, Vestibule/Buffer area, Floor, walls inside/outside and roof. Manually)

30 days 3 Hrs Automatic washing Plant & washing line




10.5 DEPOT CUM WORKSHOP LAYOUT

Different options of Depot cum Workshop Layout has been explored to

optimize the area required for planning the maintenance facilities considering

1in 7 turnouts, 1 in 5 turnouts in place of 1 in 7 turnouts and depot layout on

elevated infrastructure. The three options are discussed as below:

Option 1: At Grade Layout Plan with 1 in 7 turnouts

Option‐1 of depot layout is proposed with a curve and ramp down to depot

entry at grade level as shown in Annexure‐10.1. This layout has been planned

with all the required facilities in an area of about 13.2 hectares considering 1 in

7 turnouts and a minimum radius of 120m.

Option 2: At Grade Layout Plan with 1 in 5 turnouts

Option‐2 of depot layout is proposed with 1 in 5 turnouts instead of 1 in 7

turnouts similar to maintenance depot constructed in Mumbai Metro. The

layout plan in option‐2 is proposed in an area of about 12.5 hectares indicating

all the infrastructure facilities as shown in Annexure‐10.2. This option offers

the advantage of reduction in the land requirement for the depot i.e. about 0.7

hectares in comparison to layout in option‐1. Since, the depot constructed for

Mumbai Metro has been approved with certain restrictions and has not been

tested for its efficient and proper functioning. Thus, depot layout in option‐ 2 is

not recommended for Varanasi Metro Corridor.

Option 3: Elevated Layout plan with 1 in 7 turnouts

Option‐3 of the depot Layout is proposed with elevated infrastructure in two

levels along the BHEL station as shown in Annexure 10.3(a). Some of the

facilities in the depot viz. stabling lines, automatic coach wash plant, pit wheel

lathe, ETU shed have been proposed elevated at a height of 13m and other

maintenance and inspection facilities have been proposed at ground level. The

ground level plan and the upper level plan for the depot are shown in

Annexure 10.3 (b) and (c). The properties/buildings along the corridor have to

be acquired for this option. Land Cost including solatium is 21.85 Crore/

hectare. Also, the construction of elevated depot shall have an additional cost

implication of Rs 44 crore per hectare for the elevated portion.

In view of above and considering the cost implications and acquisition of




properties/buildings along the corridor for option‐3, it recommended to adopt

depot layout in option‐1 for Varanasi Metro Corridor.

The rake induction and withdrawal from depot to the open line will have to be

so planned that the headway of open line is not affected. For this purpose,

facilities for simultaneous receipt and dispatch of trains from depot to open

line should be created. The stabling area should be interlocked with the open

line so that the induction of train from the stabling can be done without loss of

time. The rake washing can be done at automatic coach washing plant

provided at the entry of depot i.e. before rake is placed on stabling lines.

The other movements in the depot, viz from the stabling to the inspection shed

or workshop and vice versa may be non‐interlocked. Two emergency re‐railing

lines have been provided from which emergency rescue vehicles can be

dispatched to open line in the event of any emergency. To cater to the peak

requirements, all trains would be in the service, only trains under maintenance

would be in the shed. However during the off‐peak hour in daytime,

approximately half of the trains will be withdrawn from the service. The

scheduled inspections are envisaged to be carried out during the day off‐peak

hours and night. Tower wagon shall be housed inside the ETU cum emergency

rerailing building along with the Accident Relief Train.

The stabling and the yard layout would be at grade level for least power

requirements in shunting movements and to avoid accidental rolling of Rolling

Stock resulting into accidents and damages to the property

10.6 INFRASTRUCTURE FACILITIES PLANNED AT DEPOT

10.6.1. Inspection Lines and Workshop Lines in Depot

As per the frequency of inspections indicated in Table 10.2, the visits of rakes

to Depots are as shown below in Figure 10.1:

To assess the number of lines required to maintain the rakes, following

assumptions are made:

i. For Washing of rakes, an automatic washing plant is proposed. Hence, no

separate washing line is needed exclusively for washing. However, one line

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Page 10‐7

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IOH 1 0.14 7.84 1 rake 10 days 0.261 1

POH 1 0.14 7.84 1 rake 20 days 0.523 1

Unscheduled Repair / Lifting /Wheel/Bogie sections etc. 2

Workshop Lines Provided 4

Ganeshpur Depot will have maintenance facilities and infrastructure to

maintain 56 rakes of 3 car length for the Varanasi Metro corridors. Based on

the calculations indicated in Table 10.4, the depot is proposed to be planned

with 3 inspection lines and 4 workshop lines.

10.6.2. Stabling Facility for Rakes

The rake requirement for the corridors of Varanasi Metro viz. BHU to BHEL

corridor and Beniabagh to Sarnath corridor is 38 rakes of 3 car length and 18

rakes of 3 car length respectively (Total 56 rakes of 3 cars i.e. 168 coaches) for

ultimate design. Ganeshpur depot near BHEL is planned with stabling facility of

12 lines of 9 car length each (to stable three rakes of 3 car on each line). Hence,

the depot will have stabling facility for 108 coaches.

In addition to the above stabling facility, the terminal stations viz. BHU,

Beniabagh and Sarnath have been also planned with stabling facility for 4

rakes, 4 rakes and 2 rakes respectively. At a given time, three rakes would

remain under inspection and the remaining rakes will be stabled at the

platforms of the terminal stations for the start of early morning services.

Hence, there will be sufficient stabling facility for 56 rakes of 3 cars i.e. 168

coaches and the depot will have sufficient facilities to cater to the maintenance

requirements of the rolling stock operational on the Varanasi MRTS corridors

for the ultimate design.

10.7 DEPOT CUM WORKSHOP PLANNING

As per the dimensions of the Rolling Stock, the approximate length of 3‐car

trains would be 65 m (approx). However in the design of the Inspection shed,

workshop lines and stabling lines at depot, length of 6‐car train is taken in

consideration.




I) Stabling Lines in Depot

For the design of the stabling lines in the depot, following approximate lengths

have been taken in consideration:

(i) Length of one 3‐car rake= 65 m

(ii) Gap between two 3 car trains= 10m

(iii) Free length at outer ends of the rake ( for cross pathway, Signal and

Friction buffers)= 10m each side

(iv) Total length of Stabling line = (iii)+(i)+(ii)+(i)+(ii)+(i)+(iii)= 10+

65+10+65+10+65+10= 235 m (say 240m)

Looking to the car width of 2900 on Standard Gauge, 5m Track Centre is

proposed for all the stabling lines. Thus, space between stabling shall be

sufficient to include a pathway to be constructed between tracks to provide

access for internal train cleaning and undercarriage inspection.

50% of stabling lines shall be covered with a roof in order to facilitate testing of

air conditioning of trains and their pre‐cooling under controlled condition of

temperature.

II) Inspection Lines in Depot

For the design of the Inspection Bay Lines in the depot, following approximate

lengths have been taken in

consideration:

(i) Length of one 3‐car rake= 65

m (approx)

(ii) Gap between two 3 car

trains= 10m

(iii) Cross path at each end = 10 m

(iv) Total length of Inspection line

= (iii)+(i)+(ii)+(i)+(iii)= 10+

65+10+65+10 = 160m

The inspection bay in Ganeshpur Depot shall be of 160 X 23.5m² size with three

inspection lines having sunken floor. The track spacing between the adjacent

inspection Bay Lines shall be 6.25 m.

There would be lighting below the rail level to facilitate the under frame



February, 2016 ‐10

inspection. Ramps of 1:8 slopes, 3 meter wide should be provided with sunken

floor system for movement of material for the cars. Further, 3.5 m cross

pathways are left at each end for movement of material by fork lifter/ Leister/

Hand trolley. Stinger system shall be provided for 750V DC traction power

supply to the rolling stock. 415V 3 phase 50 Hz, 230V 1 phase 50 Hz AC supply

and Pneumatic supply shall also be made available on each inspection shed

columns. Air‐circulators shall be provided on each column.

Roof and walls shall be of such design that optimum natural air ventilation

occurs all the time and sufficient natural light is also available. Each Inspection

bay will also have arrangement close by for cleaning of HVAC filter under high

pressure water jet.

III) Workshop in depot

The size of the workshop shed in

Depot shall be 160 x 44.5 m² each and

an additional covered space of 160 x

7.5 m² shall be provided in the depots

to cater for offices cum maintenance

sections, costly item store, locker

room, toilet etc. Following equipment

repair/overhaul facilities are planned

in the workshop.

Body furnishing.

Bogie.

Wheels.

Traction Motor

Axle box and axle bearing

Pentograph.

Electrical equipment like transformer, converter/inverter, circuit

breaker, relays.

Battery.

Air compressor.

Air conditioning equipments.

Brake equipment.

Door actuators.




Control and measuring equipments.

Pneumatic equipments

Dampers and Springs

Couplers/ Gangways

Cross track equipped with bogie turntables have been provided for movement

between bays.

IV) Pit Wheel Lathe

A separate building is planned for

housing pit wheel lathe (PWL) for

Ganeshpur Depot which is

approachable from workshop, ins

pection bay and stabling lines through

rail and road for placement of cars for

re‐ profiling of wheels within the depot

along with space for depot of scrap.

V) Engineering Train Unit Workshop

Since the workshop cum depot is

designed optimally, it would not be wise

to waste its capacity in maintaining the

other than passenger Rolling Stock

vehicles. Carrying these vehicles to the

inspection shed affects the Rolling Stock

maintenance as shunting is also

involved. Therefore, other vehicles like

rail cum road vehicle, tower wagons,

etc. may be housed and given required inspection attention in a separate shed

called ETU workshop, for which 2 lines have been provided in the depots.

However for the heavy lifting needs, these vehicles may be taken to main

workshop for required attention.

VI) Car Delivery Area

The newly procured coaches, which are transported by road, shall reach the

Depot‐cum Workshop by the road on trailers. To unload the coaches and bring

them to the track, provision of space, along the side of shunting neck, has to be




made for unloading of cars and other heavy materials. There should be enough

space available for movement of heavy cranes for lifting of coaches. The

unloading area should be easily accessible for heavy duty hydraulic trailers.

VII) Automatic Coach Washing Plant (AWP)

Provision to be made for Rolling Stock exterior surfaces to be washed using a

fully automated Train Washing System with a throughput capacity of

approximately six trains per hour. The AWP shall be situated at such a

convenient point on the incoming route so that incoming trains can be washed

before entry to the depot and undesirable movement/shunting over ingress

and egress routes within the depot is avoided.

VIII) Test Track

A test track of 630 mts. length will be provided beside workshop in Ganeshpur

Depot. It shall be equipped with signaling equipments (ATP/ATO). It shall be

used for the commissioning of the new trains, their trials and testing of the

trains after the IOH and POH. In compliance to safety norms, the boundary of

the track shall be completely fenced to prevent unauthorized trespassing

across or along the track.

IX) Internal Cleaning Shed

Monthly heavy cleaning of interior walls, floors, seats, windows glasses etc,

outside heavy cleaning, Front/rear Face, Vestibule/ Buffer area, outside walls

and roof shall be done manually in the interior cleaning plant designed for

cleaning of one at a time. A line adjacent to inspection shed should be so

provided that placement of rakes is possible from workshop or inspection lines

& vice – versa conveniently and with ease.

X) Train Operators Booking Office

Suitable office facility adjacent to the stabling lines at each depot should be

provided so that train operators reporting ‘On’ duty or going ‘Off’ duty can

obtain updates regarding ‘Special Notices’, ‘Safety Circulars’ and other

technical updates/information in vogue. These offices should have an attached

cycle/scooter/car stand facility for convenience of the train operating staff.

XI) Administrative Building

An administrative building close to the main entrance is planned. It can be

suitably sized and architecturally designed at the detailed design stage. A time

and security office is also provided close to main entrance. It shall be equipped




with suitable Access control system for all the staff working in the complex.

XII) Operation Control Centre and Depot Control Centre

Control of train operation will be done centrally from Operations Control

Center (OCC), which will house Traffic Control Centre, SCADA System for

Traction Power Control & Monitoring, SCADA System for Auxiliary Power, VAC

Control & Monitoring, Telecommunication, CCTV Control & Monitoring etc.

Movement of trains inside depot shall be controlled from Depot Control Centre

(DCC) located inside the depot.

XIII) Parking Facilities

a) Ample parking space shall be provided for the two wheelers and four

wheelers at the following points.

i) Close to the depot entry.

ii) Close to the stabling lines.

iii) Close to the Workshop/ IBL.

b) Space for parking of road and re‐railing equipments

Enough space for parking of road vehicle/ trailers/ trucks etc. Enough space

will also have to be earmarked adjacent to workshops. Similarly, provision of

space for parking of re‐railing equipments will have to be made close to the

main exit gate of the Depot.

XIV) Watch Towers

There shall be provision of adequate number of watch towers for the vigilance

of depot boundary.

XV) Power Supply

An auxiliary substation of 2500 KVA capacity has been planned for catering to

the power supply requirement of the depot. Details of connected load, feeder

may be worked out during detailed designing stage.

XVI) Standby Power Supply

The standby power supply is proposed through silent DG set of 2X320 KVA

adequate capacity to supply all essential loads without over loading.

XVII) Compressed Air Supply

Silent type compressor units shall be suitably installed inside the depots at

convenient location for the supply of compressed air to workshop and

Inspection sheds. Thus, the pneumatic pipeline shall run within the workshop




and inspection bays as to have compressed air supply line at all convenient

points.

XVIII) Water Supply, Sewerage and Drainage Works

In house facilities shall be developed for the water supply of each depot.

Sewerage, storm water drainage shall be given due care while designing the

depots for efficient system functioning. Past records of Municipal Corporation

shall be used to design the drainage system. Rainwater harvesting would be

given due emphases to charge the underground reserves.

10.8 PLANT AND MACHINERY

Plant and machinery proposed for the maintenance facilities at Ganeshpur

depot have been listed in Annexure 10.4




Annexure 10.1

LAYOUT PLAN FOR GANESHPUR DEPOT‐ OPTION 1




Annexure 10.2





Annexure 10.3(a)





Annexure 10.3(b)

LAYOUT PLAN FOR GANESHPUR DEPOT‐ OPTION 3 (Upper Level‐Elevated)




Annexure 10.3(c)

LAYOUT PLAN FOR GANESHPUR DEPOT –OPTION 3 (Lower Level‐ Ground)




Annexure 10.4

LIST OF MAJOR PLANT AND MACHINERY FOR BHEL DEPOT

Sno. PLANT & MACHINERY Quantity

A. MATERIAL HANDLING

Travelling over head EOT cranes for workshop 15/2T 2

Travelling over head EOT cranes for workshop 3.2T (Future) 2

Travelling over head EOT cranes for inspection bay 1.5T 2

Travelling over head EOT cranes for ETU shed 5T 1

Jib crane for workshop 3 T 2

Synchronized pit jacks system for car lifting 2

Car body stands for keeping 6 car shells 36

Dummy bogies 6

Mobile lifting jacks‐15T (Nos) 12

Mobile lifting jacks 10T (Nos) (Future) 24

Battery powered locomotive 1

Road mobile Crane 5T cap 1

Fork lift truck 3T cap 2

Fork lift trucks 2T cap 2

Pallet trucks 4

TATA Truck 1

Scissors type lifting trolley ‐ 2T capacity 2

Hydraulic trolleys ‐ 2T capacity 2

B. Wheel shop

500T wheel press 1

Vertical boring m/c (Turret Lathe) 1

Multipurpose Wheel Lathe 1

Axle turning lathe 1

Axle UST inspection machine 2

Radial drill m/c 1

Induction Heater 2

Bearing/Coupling Extractor 4





C. Bogie shop

Bosch Tank : Bogie wash/cleaning plant 1

Bogie static load testing m/c 1

Shock absorber testing m/c 1

Spring scragging &testing m/c 1

Magnaflex crack detector 1

Glowcheck crack detector 1

D. Rotating m/cs

Baking Oven 1

Dynamic balancing 1

Traction motor test console 1

Motor compressor test bench 1

Tan Delta testing instrument 1

E. Other m/cs

Re‐railing equipment 1

Mobile Wheel Turning Lathe 1

Chip crusher and conveyor for pit wheel lathe 1

Automatic Washing plant for Metro cars. 1

High‐pressure washing pump for front and rear end cleaning 1

Turn table for one car 1

Turntable for bogies 4

Driving Cab Simulator 1

Water de‐mineralizing plant (Distillation plant) 2

Painting booth for separate parts 1

Floor cleaning machine 4

Welding equipments 5

Compressor 500Cfm 2

DG set 320 KVA 3

Battery charger 2

F. Machine shop

Guillotine Shearing m/c 1





Shearing, punching & cropping 1

Universal tool cutter & grinder 1

Vertical surface grinder 1

Centre lathe 2m bed 1

Centre lathe 1m bed 1

Radial drill m/c 1

G. Test Benches/Instruments

Pneumatic test bench 1

Brake test bench 2

SPM test bench 2

Door test bench 2

Inverter test bench 1

Other test benches (MCB, RMPU etc.) 1

Oscilloscope 1

H. Furniture/material storage/Small tools

Vertical storage system for DCOS store 1

Computer MMIS with LAN connectivity 1

Storage racks LS

Industrial furniture LS

Electric and pneumatic tools LS

Measuring and testing equipments LS

Tool kits LS

Mobile safety steps 10

10. Maintenance Depot 12.02.2016 finalThe Maintenance facilities for BHU to BHEL Corridor and Benia...

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