Quality Audit report Of Coaching Depot Hazrat Nizamuddin, N …[32-2012]_CoachingDepot_N… · Page...

Quality Audit report

Of

Coaching Depot

Hazrat Nizamuddin, N Rly

Report no. 32/2012

APRIL 2012

( Audit is done by QA Mech Dte of RDSO )

of 30 Coaching depot – NZM, N Rly. April 2012

Quality audit Report of

Hazrat Nizamuddin, Coaching Depot, N Railway

1.0 Introduction - In terms of instructions issued vide Railway Board letter no. 2012/M (W)

814/5 dated 20.03.12, QA/Mechanical/RDSO/Delhi has conducted the quality audit of

Coaching Depot, Delhi of Delhi division of Northern Railway.

1.1 Audit team – Shri Satish Singh, Director/I&L/RDSO/Delhi, Shri A K Sharma, AIE-

I/I&L/RDSO/Delhi, Shri Arun Kumar, SE-1/I&L/Delhi, Shri S D Pandit, JE-

I/I&L/RDSO/Delhi.

1.2 Dates of audit - 02.04.12, 10.04.12, 13.04.12 and 14.04.12

1.3 Escorting officers – Shri Y K Vashistha, Sr CDO/HNZM, Shri A K Chopra,

SSE/Incharge, Shri S S Rathore, SSE/Stores, Shri Dilip Kumar, SSE/Technical, Shri

Ramnath Meena, SSE/Linen, Shri Sushim Gupta, SSE/Rajdhani and Shri L C Meena,

JE/Rajdhani.

1.4 Scope of audit – Primary Maintenance of Coaching Depots, Sick Line attention, Roller

bearing section, Wheel and axle section, bogie and brake gear, coupler and buffer, air

brake, availability of infrastructure M&P facilities, test benches, availability of stores

and its management, painting, etc.

2.0 Brief about depot – Nizamuddin coaching depot is located about 1 km from the

station. It has a holding of 402 coaches. It takes up primary maintenance of 14 trains,

secondary maintenance of 22 trains and 9 trains on RPC-IV.

2.1 There are 6 washing lines with WL no. 1 and 2 having 24 coaches capacity. Washing

line no. 1 is under the process of rebuilding, from April-11. WL 3, 4 and 5 have a

capacity of 22 coaches whereas WL 6 is having a 26 coaches capacity.

2.2 Sick line has three lines with holding capacity of 19 coaches & working capacity of 13

coaches. Two EOT cranes with capacity of 25/6 T & 10/3 T is available in shed. At an

avg. 7 coaches (Including 2 AC DVS) are attended in sick lines including wheel

changing & heavy repairs. At an avg. 30 coaches for special schedule in sick line are

being attended.


3.0 Strengths

3.1 System has been implemented to have a direct dialogue with the passenger, who has

recorded his complaint, on the phone number provided by the passenger and

ascertaining the exact grievance and informing the passenger regarding the corrective

action taken.

3.2 A system of testing BP/FP hoses on 100% basis using pressure at 10 kg/cm2 before

fitment in coaches is being followed.

3.3 Check of phonic wheel and speed sensor in LHB coaches has been picked up as a

mission area.

4.0 Weaknesses

4.1 Condition of catwalks on washing lines is atrocious at many locations on WL 2 to 5. It is

either having only the width of the supporting beam available or nothing at all with

gaping holes, making it impossible to attend the coaches even with minimal safety.

4.2 Illumination needs to be improved at many of the areas since it is making inspection

and attention very difficult.

4.3 Cleanliness and general maintenance of pit lines is not satisfactory. Lack of monitoring

of cleanliness, throwing of garbage randomly all over is further deteriorating the

condition.

4.4 High pressure jet cleaning pipeline with plant for cleaning at primary pit line is not

available.

4.5 Drainage system is not effective and water logging exists at many locations in the

depot.

4.6 System of provision, replacement, testing of Fire extinguishers on trains from NZM

needs to be revisited and streamlined.

4.7 External agency is carrying out the work of coach cleaning, which appeared to be

much below expected/ tolerable standards in more than 50 % of the coaches.

4.8 Washed linen, dirty linen and condemned linen are lying in the same room. The

room is in a broken condition in one corner with lot of dust and gravel, which was

found to be affecting washed linen also.

4.9 Evidence of physical stock verification of linen could not be made available. SSE/

Linen could not confirm the last date of verification. It was also seen that a large

number of blankets which were told to be condemned did not bear any

documentary evidence.


4.10 Blanket sanitization was not found to be yielding any result. Room meant for the

purpose had only a small domestic room convection heater with a few naphthalene

balls in front of it, with isolated blankets hung here and there in folded condition.

4.11 Records of D2, D3 and D4 schedules of LHB coaches need to be organized and

streamlined.

4.12 The problem of short supply of LHB spares and Wheel Sets is being faced in the depot.


Check sheet for Quality audit of NZM/NR coaching depot

Primary maintenance attention and sick line attention

(Based on CAMTECH Maintenance Manual for BG coaches

and Railway Board / RDSO’s guidelines)

SN 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 - 402 Overdue POH - 09

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

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

Coach holding –402 Overdue Sch A - 07

4. Schedule B -Quarterly (3 month ± 7 days) in rake Coach holding – 402 Overdue Sch B - NIL

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 – 402 Overdue IOH – 12 IOH activity is not being carried out at depot. Coaches are sent to NDLS and DLI.

5. 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

This is being followed.


SN Item Clause Observation 7. Examination of originating trains: 107 a of Chg. Manual


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


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

107 b of Chg. Manual

This is being followed. Rolling-in lights are provided at TKD end and DLI end for all seven platforms, except on PF 1 TKD end. FL fittings were not in working condition at four locations. Only one rolling–in hut is provided towards TKD end.

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

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

Site is conducive for conducting Rolling-in-examination. However, for trains permitted from platforms directly, one side view is possible.

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. Illumination needs to be improved at many of the areas since it is making inspection and attention very difficult.

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

This is being followed. However, defects/ discrepancies noted are being informed orally to officials concerned. System of record keeping was inevident.

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

This is being followed. Records are being maintained in the maintenance diary. 15 non-contact recorders are available, out of which 10 are working.

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

Yes.

9.1.1 Primary End On 14/04/12, rakes of 12412, Gondwana Express and 12430, Bangalore Rajdhani were checked.

i) The brake gearing should be properly adjusted

including the slack adjuster ‘A’ dimension & the

brake cylinder stroke to ensure 100% brake

power.

-do- This is being followed.


SN Item Clause Observation ii) Brake blocks should be changed in bogie sets

only -do- This is not being followed in

totality. It was informed that the depot is facing crisis of brake blocks.

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

-do- Passenger Amenities are being fitted to turn out the rake with Zero-missing amenity, to a great extent, the only constraint being occasional unavailability.

iv) Intensive cleaning of coach toilets and lavatory. -do- This is being followed. In the last six months, 1184 AC coaches (including LHB) and 437 non AC coaches have been cleaned intensively. Records are being maintained. Inspection of Rakes of 12412 and 12430 after cleaning revealed that toilet and lavatory cleaning standards need to be improved. External agency is carrying out the work of coach cleaning, which appeared to be much below expected/ tolerable standards in more than 50 % of the coaches. This was highlighted to JE-on duty, and Sr.CDO/HNZM.

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

-do- This is being followed, except train No. 14085. 12412 and 12430 have a pit time slot from 0800-1400 hrs. on W/L no. 2 and 1400-2200 hrs. on W/L no. 6 respectively.

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

-do- All washing lines, 1 to 6 are pit type. Washing line 1 is under rehabilitation. Welding facility is available on all lines. Condition of catwalks on washing lines is atrocious at many locations on WL 2 to 5. It is either having only the width of the supporting beam available or nothing at all with gaping holes, making it impossible to attend to coaches even with minimal safety. High Pressure Jet cleaning arrangement is not available on any Washing line. Pit/ Column lights are not available.


SN Item Clause Observation vii) Adequate gang strength with proper supervision -do- Cleaning of all trains

outsourced. Sr.CDO/HNZM highlighted that as against a sanctioned strength of 1002, 737 men are on-roll.

9.1.2 The Other End

i) Whenever the lie-over is more than 2 hours at the

platform or the rake is stabled in the yard, the rake

should be locked and positive security should be

provided.

-do- This is being followed. Verification done on rake of Train no. 12430 and the conditions found complied with.

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

-do- Partially available. Drains’ covers & concrete path way are not available. No watering arrangement on PF no. 3 and 4. Water pressure becomes low at times on all the platforms. It fluctuates from 12-40 lpm on PF 1 to 6 on opening 10 hydrants and from 5-22 lpm on opening 20 hydrants. Water pressure at PF 6 was adequate. Inspection lights along the track are also not 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- Sr.CDO/HNZM informed that no such joint safety certificate is being issued at divisional level

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


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

Stipulated RPC-4 conditions are available on stabling line no. 22. It was highlighted by Sr.CDO/ HNZM that keeping in view the workload of HNZM depot; such facilities are required on more stabling lines.

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 This is being followed. Cleaning activity is outsourced except for Shatabdi Complex. Cleaning compounds of Johnson Diversey/ Eureka Forbes/ Pudumjee Hygiene are prescribed and being used. Isolated cases were seen in which some local brands were used in emergencies.


SN Item Clause Observation

System of accountal, issue and consumption of cleaning chemicals was seen. Supervisory checks are being conducted at regular intervals.

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

Rakes are being protected properly with scotch block & locking arrangement. Verification done in Rakes of 12412, Gondwana Express and 12430, Bangalore Rajdhani.

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

109 (b) of Chg.Manual

This is being attended. Checked on coach nos. WGACCN 06108, WGSCN 96204, 96221, 07246, GS 12409, WACCN 15607, WACCW 96059 AND WFAC 3028.

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

109 (c) of Chg.Manual

This is being followed. Toilet cleaning needs to be improved further. Toilets appeared to be splashed with water than cleaned. Distinct marks could be observed on the wash basins and pans in majority of the coaches of 12430.

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

This is being followed. Betel stains and dried left-over food stain marks in the passages and vestibule area could be observed. Please refer item 12.3 above for coach numbers.

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

109(e) of Chg.Manual

This is being followed. Betel stains could be observed. This needs to be improved. Please refer item 12.3 above for coach numbers.

12.7 Cleaning of buffers and screw couplings 109(f) of Chg.Manual This is being 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


(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


13. Conditions required for maintenance of 24 coach trains (Railway Board’s letter No.98/M(C)/137/19 Pt.I dt.28.7.99 & 5.5.2000

110 of Chg.Manual

13.1 Infrastructural requirements 110(a) of Chg.Manual

(i) 24 coach length fully equipped pit line. 110(a)(i) of

Chg.Manual

At present WL 2 & 6 is having a capacity to accommodate 24 & 26 coaches respectively.


SN Item Clause Observation (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

High pressure jet cleaning pipeline with plant for cleaning at primary

pit line is not available. (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

Condition verified for attention in PF no. 6 at NZM. Water Hydrants found sufficient. At platform no.3 & 4, there is no provision for water hydrants. Water leakage was observed in a number of Water hydrants.

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

110(a)(iv) of Chg.Manual

Adequate number of RTRs is available. However, it was observed that gauges provided on these equipments were not calibrated.

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

(i) Air brake with twin pipe graduated release system 110(b)(i) of Chg.Manual

Yes.

(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

Yes.

13.3 Maintenance practices and system related requirements

110(c) of Chg.Manual

On 14/04/12, rakes of 12412, Gondwana Express and 12430, Bangalore Rajdhani were checked.

i) The integrity of the rakes to be maintained. 110(c)(i) of

Chg.Manual

This is being followed, except in cases of non-availability of coaches vice DVS.

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

110(c)(ii) of Chg.Manual


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

110(c)(iii) of Chg.Manual


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


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

110(c)(v) of Chg.Manual

This is being followed. Endorsement in this regard is also being done in Air Brake Diary.

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

110(c)(vi) of Chg.Manual

Not applicable to the depot.

vii) Provision of audio visual alarm system on the locomotive

110(c)(vii) of Chg.Manual

Not applicable to the depot.

14.

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


This is being attended through outsourcing.

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

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

This is being followed. Checked in 12430, Bangalore Rajdhani. WACCN 99141, one FE was found with expiry date over. In coach no. WACCW 00118, FE no. 917 and 923,


SN Item Clause Observation Each AC coach 2 nos

Each Pantry car 4 nos

Each Generator van

2 nos

due date of testing had passed long back, but these had been continued to remain on coach without fresh testing, though stock was available in stores. System of provision, replacement, testing of Fire extinguishers on trains from NZM needs to be revisited and streamlined.

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

DCP Fire Extinguisher and wooden wedges are being provided by C&W, same is being ensured by maintenance C&W engineer. Other items being supplied by their respective Department. The rake of 12430 Bangalore Rajdhani checked for availability of such equipments on dt. 14/04/12 and equipments were found available.

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


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 card is being prepared by C&W Department and provided in outgoing rake. However, Joint check with RPF is not being carried out. DRS card is not being received back.

(ii) On arrival of the train at the destination station,, the Engineer (C&W) staff and electrical staff shall check the rakes jointly with a representative of RPF and comparison may be made with original report.

111(5)(b) of Chg.Manual

Joint report is made in reported case of theft only.

18. Coach Maintenance History Card 111(k)(i) of

(i) Every coaching depot shall have computers for maintaining the coach maintenance history in a software programme which should be compatible with the programme of the coaching workshop.

Chg.Manual Though computers are available, coach maintenance management software is not available with Depot. Coach History Cards up to depot level are being maintained.

(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

This item pertains to Workshop.

19. Primary/Secondary maintenance 19.1 The rakes/ coaches of all trains should be given a

Primary/Secondary Maintenance examination as prescribed by the Chief Mechanical Engineer of

113(a) of Chg.Manual



SN Item Clause Observation the Railway and as per Appendix F of Chg.Manual

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


This is being followed to the extent of availability of water.

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.



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.


This is being followed. and no “S” marked rejectable defects are allowed. .

19.5 The following items of undergear 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

This is being followed. In other than Shatabdi/ Rajdhani Coaches, it is being done on monthly basis.

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

113(e)(ii) of Chg.Manual


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


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.


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

iii) Door lock handles 113(f)(iii) of Chg.Manual

iv) Tower bolts 113(f)(iv) of Chg.Manual

v) Window shutters should neither be tight nor loose 113(f)(v) of Chg.Manual

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


SN Item Clause Observation vii) Window frame 113(f)(vii) of

Chg.Manual

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

113(f)(viii) of Chg.Manual

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

113(f)(x) of Chg.Manual

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

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

113(f)(xii) of Chg.Manual

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

Records of DDR diary for 13/04/12 and 14/04/12 were checked. It is, however, not possible to correlate the dates of previous attentions done on a particular coach, in the absence of a monitoring software.

20. Schedule ‘A’ Examination 114 of Chg.Manual Rake of 12412 checked.

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


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



iii. The specified items of work should be attended

during Schedule ‘A’ examination, i.e. monthly examination:-


Records indicate only the fact of having completed ‘A’ schedule. Details regarding checking of items as prescribed during the schedule could not be made available.

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


ii. The specified items of work should be attended. 115(b) of Records indicate only the fact of having completed ‘B’ schedule. Details regarding checking of items as prescribed during the schedule could not be made available.

iii. Brake system maintenance

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

Chg.Manual This is being followed.


SN Item Clause Observation 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

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

c. Thorough inspection and repairs of brake gear components.

115(b)(iv) of Chg.Manual

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

115(b)(v) of Chg.Manual

e. Touching up of painted portion, if faded or soiled. 115(b)(vi) of Chg.Manual

22. IOH attention

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

Sick line has a three working lines with holding capacity of 19 coaches and working capacity of 13 coaches. Two EOT cranes with capacity of 25/6 T and 10/3 T are available in the shed. On an average, 7 coaches (including 2 AC DVS) are attended in sick line, including wheel changing and heavy repairs. On an average, 30 coaches are attended for special schedules in sickline. IOH schedule is not being attended at NZM depot. .

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

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

22.3 Brake system : ‘C’ schedule maintenance (IOH)

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

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

117(a)(vii) of Chg.Manual

22.5 Other assemblies maintenance

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

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


SN Item Clause Observation 22.7 Touching up damaged paint of coaches on

outside as well as inside. 117(a)(iii) of Chg.Manual

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

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

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

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

117(a)(vii) of Chg.Manual

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

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

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

117(a)(x) of Chg.Manual

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.


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

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

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

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

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


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.

Yes. Washing, storage and distribution is being done through outsourcing.



Washed linen, dirty linen and condemned linen are lying in the same room. The room is in a broken condition in one corner with lot of dust and gravel, which was found to be affecting washed linen also.

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

Evidence of physical stock verification of linen could not be made available. SSE/ Linen could not confirm the last date of verification. It was also seen that a large number of blankets which were told to be condemned did not bear any documentary evidence. Gate Pass no. 29 of 19/03/12 showed movement of condemned bed sheets to SSB, but it was informed that same were not received there and returned.

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.


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

This is being followed. Records of linen check at supervisory level were seen. Super-check records at Depot officers’ level is being carried out. It was informed that system exists for rejection/ return of any soiled/ dirty linen entering the circuit after washing. System exists for forwarding necessary advices in regard to imposing deductions from the contractor’s bills in case of default.

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

This is being followed. As per the daily position of linen availability on 12/04/12, 28588 bed sheets, 19684 pillow covers, 42311 face towels and 1392 blankets were available at the depot.


SN Item Clause Observation 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

This is being followed to the extent of availability.

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


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

This is being followed. However, blanket sanitization was not found to be yielding any result. Room meant for the purpose had only a small domestic room convection heater with a few naphthalene balls in front of it, with isolated blankets hung here and there in folded condition.

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

This is being followed. Records of the same are available. 09-10 : 92 complaints 10-11 : 111 complaints 11-12 : 29 complaints

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


24. Pest / Rodent Control Mr.Anant Kishore, JE-I

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


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

This is being followed. Unreserved coaches are not covered.

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.

AC-Weekly Pantry Cars- Weekly. Non- AC: Bimonthly.

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

This has been clearly specified. Chemicals like ICON powder, Roachex, Nuvan, Maxforce IC, Dart Super powder and Express-35 have been prescribed alongwith their concentration/ dilution ratios. As far as pest/ rodent control is concerned, no record pertaining to consumption of quantities during treatment or issue and opening of sealed



containers of chemicals could be produced. Only number of cockroaches and rats found as a consequence of treatment is being recorded.

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.

AC-Weekly PC-Weekly Non-AC: Bimonthly.

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


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

This is not being 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


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

This is being followed. Coach nos. WGSCN 92488, WGACCN 06108, GS 12461, WFAC 3028 were checked and found in order.

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

This is in practice subject to availability of spare Pantry Car in the depot.

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

Reduction in level of infestation is being monitored.

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

This is being followed. Records of the same are available. 09-10 : 98 complaints 10-11 : 35 complaints 11-12 : 24 complaints

25. Passenger amenities provided in various types

of coaches as specified

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

Checked rake of 12412 and coach no. GSCN 09241 and 96270. Minor deficiencies could be noticed.

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

In all washing Lines, unified maintenance is done.

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

Para 1009 of Chg manual

Indicate quantum of rejection in addition to observation

27.1 Wheel and axle Para 1009 a of Chg manual

Record of detachments checked in Sick Line. Month-wise details of wheel defects noticed during last six months is as under :



Oct’ 11 - 07 nos. Nov’ 11 – 05 nos. Dec’ 11 – 04 nos. Jan’ 12 – 03 nos. Feb’ 12 – 05 nos. Mar’ 12 – 08 nos. TOTAL : 25 nos.

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


ii) Limits for flat tyres The limits for permissible maximum flat surfaces on tread for BG ICF coaches is 50 mm (reference Rly. Bd.'s Letter no. 83/M (N)/960/1/Vol I dated 15/18.3.99)


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:


a) Shattered Rim Yes.

b) Spread Rim Yes.

c) Shelled Tread Yes.

d) Thermal Cracks Yes.

e) Heat checks Yes.

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.


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


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.

This is being followed. Month-wise details of roller bearings failures noticed during last six months is as under:- Oct’ 11 - 0 nos. Nov’ 11 – 0 nos. Dec’ 11 – 0 nos. Jan’ 12 – 0 nos. Feb’ 12 – 0 nos. Mar’ 12 – 0 nos. TOTAL : 0


SN Item Clause Observation 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.


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.


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


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


ii) If temperature is found above 800 C, the affected

coach will be detached. This is being 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 This is being 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.


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

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


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


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


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

This is being followed at the Depot level further to workshop’s off-POH issue.

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

RDSO spec and STR This is being followed at the Depot level further to workshop’s off-POH issue.

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

This is being followed at the Depot level further to workshop’s off-POH issue.

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

Snack table in each bay. Mirrors in each bay

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

These are being followed partially due to availability constraints.


SN Item Clause Observation Magazine holders on partition wall Bottle and tumbler holder

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 followed.

RB letter no. 2009/M (C)/141/2 dtd 25.08.09

This is being followed. Primary - Ernakulam & Pune Duronto Secondary - Chennai & Secunderabad Duranto

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 & rolling out is being attended at NZM by train duty staff as NZM is terminal point for Duronto trains.

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.


Not applicable to NZM depot.

iv) Cleaning of Vinyl wrapping on Duranto rake coaches Mild detergent should be used with normal jet of water. High pressure water jet should not be directed towards Vinyl wrapping.

RCF’s letter no. MD 22.151 dtd 09.02.10


29.6 Attention of air springs ED/Carrg/RDSO’s letter no. MC/CB/MM dtd 09.09.2009 & Maintenance manual of air spring for mainline ICF bogie coaches RDSO/2009/CG/CMI-01, Sep’09

Procedure for rolling – in examination: As train passes the nominated point, C&W staff should watch out vigilantly loose / hanging / broken under gear parts of the coaches special attention should be paid to air springs in case of coaches provided with air springs at secondary suspension stage. It should be ensured all the air springs are in inflated condition by noting that the levelling valve lever is in horizontal position. In case it is not feasible to inflate the air springs of any particular coach, these should be isolated by air spring isolating cock and speed of train should be reduced to 60 Kmph or the coach should be detached.

This is being followed. SrCDO/NZM informed that problems faced by depot have been highlighted to superior officials.

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.

This is being followed. 10-11 : 3026 11-12 : 2053

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


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.



SN Item Clause Observation 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.

Partially available. 1. The pits available at

washing lines are filled with water and water logging is seen at various locations.

2. Catwalks are broken at many locations on WL 2 to 5 so badly that it is difficult to attend to the rake.

3. Due to various air leakages, the air pressure built up late in RTR.

4. Gauges of Rake test rigs are not calibrated.

30 Passenger satisfaction

30.1 OBHS & escorting of trains

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

Yes

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

05 Rajdhani Express trains.

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

02 Duranto trains.

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

05 trains

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

Average PSI remains around 88% for all trains covered under OBHS.

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.

Feedback mechanism is found to be existing. Further, Sr.CDO/NZM has implemented a system of speaking to the passenger, who has recorded his complaint, on the phone number provided by the passenger and ascertaining the exact grievance and informing the passenger regarding the corrective action taken.

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.

This is being followed. Passenger complaints in the last three years, inclusive of cleaning, linen, OBHS and pest control are as follows: 09-10 : 237 10-11 : 223 11-12 : 97

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.

12 rakes of Rajdhani & Duranto covered by out



sourcing. Water jet machine, Vacuum Cleaner & scrubber M/c are available with contractor. Standards of cleaning were not seen to be of expected/ tolerable standeards, especially toilets and lavatories.

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

Upholstery and Carpet cleaning of the coaches is outsourced and monitoring format is endorsed only after satisfaction by authorized official from Railways’ side.

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

Yes

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

Yes

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.

This is not being ensured due to conditions prevailing in the station and depot area.

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

Garbage and left over food items are disposed by cleaning staff in Dust Bins located in washing line area.

c) Sustainable garbage collection and disposal system

Garbage and left over food items are disposed by cleaning staff in Dust Bins located in washing line area.

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

Drainage system is not effective and water logging exists at many locations in the depot.

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

Fumigation is not carried out in the depot.

f) Monitoring the functioning of OBHS and CTS scheme.

Monitoring is being done through Test Check Protocol and penalties are imposed in case of non-conformities found during inspection.

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.

Inspection under OYTS Scheme is being carried out and deficiencies are made good which are noticed during such inspection.

ii) Quality of linen supplied on trains:

a) Availability of clean and hygienic linen to passenger through washing quality, adequate

Adequacy of Linen in terms of quality and quantity was of a


SN Item Clause Observation quantity, replenishment with new linen on age / condition basis, use of washable blankets and appropriate quality of packing.

reasonable standard, with a definite scope for improvement in inspection standards. With the available method of stacking of new linen/ blankets, FIFO cannot be ensured.

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

Work of cleaning of Linen is outsourced.

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

The activity is outsourced and streamlined.

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

Periodicity of POH is being followed.

31.2 Attention to following components are being given as per Alsthom manual guidelines and guidelines circulated by RDSO. Phonic wheel / speed sensor. Dump valve Earthing device. Control arm Dampers

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

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

Alsthom manual and OEM manuals

Attention to components is being given as per ALSTOM/OEM manual. LHB coaches have arrived from June’ 11. It was informed that D2, D3 and D4 schedules are being conducted regularly. However, records could be seen only from 07/04/12 onwards. Coach no. WLACCN 7935 was in sickline for D4 schedule, from 10/04/12, waiting for CBC. Records of D2, D3 and D4 schedules of LHB coaches need to be organized and streamlined.

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

Para 1009 a (iii) of chg manual

Wheels Sets are examined during maintenance and coaches are marked sick for various types of wheel defects. Please see item 27.1 above


SN Item Clause Observation Shelled Tread Thermal Cracks Heat checks

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

Instructions are being complied with.

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


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


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

Instructions are being followed in the depot.

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

Adequate wheel sets for LHB coaches are not available in depot. Requirement- 20 per month. Availability- 04 per month.

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.


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


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


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


31.4 Phonic wheel/Speed sensor 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.

This is being followed. Also, a special drive has been conducted in the recent past in this rergard.

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

This is being followed. Appropriate records are maintained and same could be


SN Item Clause Observation quarterly schedule or whenever required. correlated.

iii) The phonic wheel and speed sensor should be procured through OEMs/OEMs’ approved sources only. M/s KB and M/s FTIL are OEM of this item.

Procurement of these items is being done by Store depot.

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


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

OEM guidelines This is being followed.

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.

Out of 50 Coaches checked in the depot, following observations recorded: (i) Nos. of Units checked: 100

Units. (ii) Nos. of Units found

deficient: 60 Nos. (iii) Units found functional: 40

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

12 Nos. Earthing unit Assemblies found with deficiency of Earthing Wire.

Junction box in broken/damaged condition.

Nil

31.7 Disc brake attention: OEM guidelines

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

Brake pads are renewed on condition basis & adequate spare is not available at NZM.

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


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

In-house attention is being given.

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

Yes

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

Yes


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 lath - - 1 Not available

Whiting jacks (5 Nos.) - 1 set 1 set Not available

EOT crane 20T - - 1 Available 25/6 T

Coach Shunter - 1 2 Not available

Welding Plant 1 2 4 Available

Gas Cutting Equipment 1 2 2 Available

Vacuum Exhauster 1 2 2 Not available

Air Compressor 30 cfm 1 2 2 Available

Portable Vacuum Testing Equipment - 1 1 Not available

Portable Air Compressor - - 1 Not available

2T Tram beam hoist 1 1 2 Not available

Sewing machine - 1 1 Available

Truck 10T - - 1 Canter available

Light Coml. Vehicle 1 1 1 Available

Fork lift truck - - 1 Available

Lister truck 1 1 2 Available

Car Washer - 1 1

Portable Trolley Light 2 4

Cotton waste soaking plant 1 1 1 Not available

Wood cutting saw machine - 1 1 Not available

Hand shearing machine - 1 1

Portable Furnace 1 1 2

Centre Lath - - 1 Not available

Bogie Manipulator - - 1 Not available

Ultrasonic Testing Apparatus 1 1 1 Not available

Tool post Grinder - 1 1 Available

Vacuum Cleaner 1 2 3 Available


Description Minor

Depot

Medium

Depot

Major

Depot Observation

Pressure Jet Cleaner 1 2 4 Not available

Tools

a. Pneumatic Hand Tools

i. Grinder 1 1 2 Not available

ii. Drill 1 1 2 Not available

iii. Chipper / Buster - 1 2 Not available

iv.Riveter - - 1 Not available

b. Electric Power Tools

i. Pop Riveting Gun - 1 1 Available

ii. Drill - 1 1 Available

iii. Bolt Tightner - - 1 Not available

c. Hand Tools As required Available

d. Test Bench

i. Water Tank Test Rig - 1 1 Not available

ii. D.A. Valve Test Bench - 1 1 Not available

iii. Vac. Cyl. Test Bench - 1 1 Not available

iv.Slack Adjuster Test Bench - 1 1 Not available

v. DV Test Bench - 1 1 Available

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

e. Office Equipment

i. Computer system 1 1 1 Available

ii. Plain Paper Copier 1 1 2 01 available

iii. Telefax 1 1 Not available


Annexure - II

Emergency materials required for platform (C&W) office

Sl. Items Required Observation

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

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

3 Draft cotter with 'U' pins 1no. Not available

4 Draft link complete 2 sets Available

5 Equalizing Stay rod with pins ( Non-modif. & Modif.) 1 set each Available

6 Anchor link with securing studs 1 set Available

7 Truss Bar Hanger with Pins & Cotters 2 sets Available

8 Bolster suspension Link (Stirrup Link) with Pins &

Stones 2 sets

Available

9 Axle Box Face Cover (ICF) with securing nuts & Pins 2 sets Available

10 'O' Ring 2 nos. Available

11 Grease Servogen 4 kgs. Available

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

13 Angle cock 2 nos. Available

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

15 M.U. washer 10 nos. Available

16 Teflon Tape 1 no. Available

17 Portable Air Pressure Gauge 1 no. Available

18 Pressure Gauge BP & FP 2 each Available

19 BP & FP Air hose 2 each Available

20 Guard Emergency Application Valve 2 nos. Not available

21 Wooden Plug (various sizes) 10 nos. Available

22 Wooden wedge 4 nos. Available

23 G.I. wire Adequ. Qt. Available

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

25 Push cock 5 nos. Available

26 Spl. Jack for changing Eq/Stay rod 1no. Not available

27 Slide wrench, Pipe wrench-24'' 2 nos Available

28 Hydraulic Jacks 2 sets Not available


Annexure – III

Details regarding coaching depot

Depot name and division: Hazrat Nizamuddin

1. Coach Holding

Mail/Expresses coaches with conventional coupling 192

Mail/Expresses coaches with CBC coupling Nil

Rajdhani/Shatabdi coaches (conv) 140

LHB coaches (Rajdhani/Duronto) 52 Raj.+18 Duranto=70

Shatabdi Coaches (conv) Nil

Shatabdi coaches (LHB) Nil

Passenger coaches Nil

OCV’s Nil

Grand Total 402

2. Maintenance attention of at depot

PM of Mail/Expresses train with secondary attention at other end 07

PM of Mail/Expresses train with round trip attention at other end 07

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

Total PM attention at depot: 14 trains

Total SM attention at depot: 22 trains

Total Round trip attention at depot: 08 trains

3. Pit line attention

24 coach pit with catwalk and high pressure water jet facility/watering

facility at per CAMTECH’s guidelines

At present washing line No.2 &

6 is having 24 & 26 coach

length respectively, but high

pressure water jet facility is not

available.

24 coach pit facility with catwalk At present washing line No.2 &

6 are having 24 & 26 coach

length respectively.

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

collected)

Washing line no.3, 4 & 5 having

coach facility of 22 coaches with

broken 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

Only line No.22 is available with

24 coach length facility is

available.

Compressed air with reservoir and ir dryer/moisture trap facility with test

rig (RTR)

Dryer is attached with two

electric compressors.

Facility for welding at Yard attention Two portable welding sets are

available for yard attention.

Night maintenance facility with overhead/pit light as per CAMTECH’s

guidelines

Only over head lights are

available.


4. Sick line facility

Coach lifting facility with overhead crane 02 nos. of EOT cranes are

available in sick line with

capacity 25 & 10 ton

respectively.

Coach lifting facility with JMP jack/hydraulic jack 15 ton: 12 ; 35ton:14

Total coach accommodation

With pit attention Without pit attention

With pit attention=08 coaches

Without pit attention=10coach

+1 coach length is being utilized

for wheels stabling.

Facility for compressed air with test rig (SCTR) 01 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 at washing line & train duty.

6. Availability of staff for coaching maintenance as per Yard stick. Shortage exists compared to sanctioned

strength.

7. Training status of supervisor and staff –No supervisor is running over due for refresher course upto

March 2012.

8. Availability of critical/ safety stores and storage system. The problem of short supply of LHB Type

Dampers and LHB Type Wheel Sets is being faced in the depot.

9. Availability of coaches as per rake link with maintenance spare. Spare coaches are not available as per

requirement.

10. Bottlenecks / limitations of system / depot. Condition of catwalks on washing lines is atrocious at many

locations on WL 2 to 5. It is either having only the width of the supporting beam available or nothing at all

with gaping holes, making it impossible to attend to coaches even with minimal safety. Partially available

drains’ covers & concrete path way are not available. No watering arrangement on PF no. 3 and 4.

Water pressure becomes low at times on all the platforms. Illumination needs to be improved at many of

the areas since it is making inspection and attention very difficult.

11. Safety performance record: Cases of en-route detachments are quite less which shows that safety

instructions are being complied with during maintenance.

12. Performance of critical spare: This is a cause for concern.

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