Quality Audit report Of Coaching Depot Jaipur, N W...

Quality Audit report

Of

Coaching Depot

Jaipur, N W Rly

Report no. 11/2012

APRIL 2012

(Audit is done by CRSE, NR )

of 34 Coaching depot – Jaipur, N W Rly April 2012

Quality audit Report of Jaipur Coaching Depot, NW Railway

1.0 Introduction Quality audit of the maintenance practices followed at Jaipur Depot were carried out as per Railway Board’s letter no. 2012/M(W)/814/5 dt. 20.03.2012 and RDSO letter no. QAM/Quality Audit Dt. 21.03.2012. Following team members were associated for conducting Audit from 03.04.12 to 06.04.12. 1.1 Audit Team - Sri. Shankar Mazumdar, CRSE/Chg, NR, Sri. Rajesh Dhawan,

Dy. CME/IT, NR, Sri. Nusrat Ali ADME/Chg/DLI, Sri. Rakesh Sharma, SSE/MB, Sri. Balraj, CDO/KLK, Sri. Tauqir Ahmad, SSE/Cnl/HQ, Sri. V.K. Tyagi, SSE/SRE,Sri. Parduman Singh, SSE/FZR, Sri. Devendra Pingolia, SSE/IT

1.2 Escorting officials from depot - Sri. Manoj Jain, Sr. DME/C&W/JP, Sri.

Sanjay Sharma, ADME/C&W/JP, Sri. G.N. Jha, CDO/JP, Sri. M.K. Singh, SSE/Incharge, Sri. Ranjan Dwivedi, SSE, Sri. R.C. Rajora, SSE, Sri. B.K. Sharma, SSE

2.0 Strengths

2.1 Compact tool kit shoulder bag has been issued to all artisan staff. This kit bag

contains a practical list of all tools required for routine maintenance.

2.2 For all type of specialized nature of work (contracts, fire extinguishers, calibrations of gauges etc.) which requires close monitoring, dedicated supervisor and staff has been nominated. Gauge calibration and fire extinguisher testing/re-filling is being done in-house. The depot has in-house facility for BP/FP gauge calibration & Hydraulic pressure testing of Fire extinguishers.

2.3 The depot has one BTPN tank for water storage purpose in washing line. Water is filled in the BTPN tank from overhead water tank. Once BTPN tank is filled, water is supplied at high pressure through a dedicated booster pump of 10 H.P. for each washing line. Availability of water at high pressure in washing line ensures better cleaning of coaches.

3.0 Weaknesses

3.1 Thirteen trains are being given terminal examination at Jaipur, but there is no stabling line for RBPC IV maintenance. All trains are being maintained on platforms only. On the non-platform end there is insufficient illumination and hence inspection specially at night is difficult.

3.2 Record keeping of A & B schedules carried out at depot is not as per

CAMTECH manual. Schedule A - Record is being maintained on separate register which does not cover items 1.1, 2, 4.4.8, 4.4.10 & 9.5 of Annexure F of CAMTECH manual.


Schedule B - Record is being maintained on separate register which does not cover item 3.3 of Annexure F of CAMTECH manual.

3.3 Cleaning of coaches is being done contractually however, mechanised cleaning system is not in vogue. Standard of cleaning leaves room for improvement.

3.4 Availability of Standard Facilities

As per CAMTECH manual major depot (more than 250) should have one under floor pit wheel lathe. Jaipur depot has holding of 553 coaches. Wheels are being transported by road to Ajmer workshop has increasing lead time for repair in sick line. With the arrival of LHB coaches availability of wheel lathe will be critical factor for reducing ineffective. Besides there is shortage of coach shunter, wood cutting saw machine, hand shearing machine & pneumatic hand tools.

3.5 An analysis of the depots sick marking was done (details provided in

Annexure-C) The major causes of sick marking are - i) Wheel defects (14% of total DVS 2011). Majority of the wheel defects

are due to Hollow Tyre. ii) Bogie Suspension defects (14 % of total DVS 2011). Majority of defects

are due to Dashpot Assembly defects. Sick marking by the depot can be significantly reduced if proper analysis is done along with workshop to identify the possible causes for the same & take remedial action.

3.6 While checking availability of critical/safety stores and storage system it was

found that no separate place has been demarcated for inflammable material.

3.7 Water logging was observed in drain of washing line no. 3.

3.8 As per Railway Board’s policy, OBHS are to be provided in eight trains. At present only two trains have been covered under OBHS.

3.9 Linen Management 3.9.1 Blankets are wet cleaned instead of dry cleaning.

3.9.2 Piping of blankets is not attended. 3.9.3 Sufficient number of steel body trolleys are not available 3.9.4 Polyvastra bed sheets are yet to be stocked for 1st AC coaches. 3.9.5 Adequate space for storage of linen stock is not available. 3.9.6 Calendaring machine in the laundry was not working properly. 3.9.7 Only one air dryer was in working order against the requirement of two.

3.10 Pest & Rodent control 3.10.1 Level of infestation for second month was not available. 3.10.2 No glue board was found in coach no.97117 WACCN. 3.10.3 Test check protocol register does not indicate required quota vis-a-vis actual

inspections done by various level of supervisors & staff.


LIST OF ANNEXURES

Annexure I Standard facilities in carriage maintenance depot as per

CAMTECH manual

Annexure II Emergency material required for platform C&W office

Annexure III Details regarding coaching depots

Annexure A1 List of Tools to be kept in tool bag

Annexure A Six months statement of IOH done at Jaipur

Annexure B Pit occupation chart and rake link chart

Annexure C Cause wise analysis of primary sick coaches

Annexure D Wheel consumption record

Annexure E Performa of dispatching defective wheels to Ajmer

workshop

Annexure F Details of detachment of secondary maintenance coaches

Annexure G Check list of inspection report by officers

Annexure H Sample inspection note of officers regarding monitoring of

CTS work

Annexure i Analysis of passenger complaints

Annexure J Photographs


Quality Assurance Directorate (Mechanical) RDSO Lucknow

Check sheet for Quality audit of coaching depot

Primary maintenance attention and sick line attention

(Based on CAMTECH Maintenance Manual for BG coaches

and Railway Board / RDSO’s guidelines)

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 – 553 Overdue POH – Nil

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 – 553 Overdue Sch A – Nil

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

Coach holding – 553 Overdue Sch B - Nil

5. IOH attention - detach coaches Periodicity of IOH attention:

Coach Category

Periodicity

New coach at interval of 12 months in Depot

Rajdhani Satabdi (Conv)

at interval of 9 months in workshop

Mail / Express at interval of 9

months in depot

Passenger at interval of 9

months in depot

Other OCVs at interval of 12 months in depot

Tolerance for IOH may be kept as + 30/-0 days. Maintenance activities to be carried out during schedules should be as per Appendix-F & G. For IOH attention of newly built coaches, guidelines as circulated vide RB’s letter no. 2007/M ( C)/141/1 dtd 06.08.09

Coach holding – 553 Overdue IOH –Nil Average arising of IOH of Mail/Exp/Pass/Coaches is 25 coaches per month. The list of coaches attended during last 6 months is attached as per Annexure A. All the coaches are being detached in due time. Overhauled Bogies are being received from Ajmer workshop and 100% bogies are being changed during IOH.

6. Primary maintenance schedules are 112(b) of Chg.Manual A, B & C/IOH 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.

being carried out at stipulated intervals.

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

Yes, Fit Memos being Issued before despatch of train

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

107 b of Chg. Manual

Yes, being complied with

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

107 (b)(i)(a) of Chg.Manual Yes, Complied with

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

107 (b)(i)(d) of Chg.Manual Available

8.3 As the train passes the nominated point, C&W staff should watch out vigilantly for loose/hanging/broken under gear parts of the coaches, any unusual sound coming from the coaches or any other abnormality in the coaches.

107(b)(iv) of Chg.Manual Yes, being complied with

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 Individual axle box temperatures are being measured using electronic temp. measuring device

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

Being followed

9.1.1 Primary End

i) The brake gearing should be properly

adjusted including the slack adjuster

‘A’ dimension & the brake cylinder

stroke to ensure 100% brake power

-do- Being complied with. Depot is having all BMBC coaches except SAB equipped 02 coaches (Chair Cars).

ii) Brake blocks should be changed in bogie sets only

-do- Brake blocks are being changed in wheel sets due to introduction of BMBC independent slack adjusting facility available on each wheel set. However, sufficient brake blocks are available.



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

-do- Being Complied with, however, magazine pockets and glass holders are recouped in GSCN coaches as per the availability of items.

iv) Intensive cleaning of coach toilets and lavatory.

-do- Being followed. Cleaning is being done on contract basis

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

-do- Being followed.

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

-do- Available

vii) Adequate gang strength with proper supervision

-do- Available. However, due to shortage of staff (614 on roll against sanctioned strength of 698) slight crunch is being faced for maintenance of trains.

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- Being complied with, rakes having lie over more than two hours are being stabled in yard.

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

-do- Available except 110 V inspection lights throughout the track length for night examination of under gear. However, hand held rechargeable torches are being used by staff to carry out examination during night.

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- Being followed at Zonal/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

Checked depot rake link and pit occupation chart, copy attached as Annexure B.

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

Checked for any attention without facility – water filling is being done by commercial staff. No stabling line is available on platform.

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 Being Complied with. RDSO Cleaning agents I & II physically checked and found OK.

12.2 It should be ensured that the rake/coach is protected with proper

109 (b)(i) of Chg.Manual Being complied with. Proper arrangement for line



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

protection is available in washing line.

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

109 (b) of Chg.Manual Being complied with.

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

109 (c) of Chg.Manual Being followed as per manual.

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 Being followed as per manual, except Vacuum cleaning.

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

109(e) of Chg.Manual Being followed as per manual.

12.7 Cleaning of buffers and screw couplings

109(f) of Chg.Manual 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 Being followed.

(ii) Screw coupling threads should be cleaned with wire brush to remove all dirt and dust. Thereafter, it should be cleaned and given a light coat of oil. Oiling should be done on slack adjuster also

109(f)(ii) of Chg.Manual Being followed.

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

110 of Chg.Manual

13.1 Infrastructural requirements 110(a) of Chg.Manual

(i) 24 coach length fully equipped pit line. 110(a)(i) of Chg.Manual Three Nos. Pit lines each is having 26 coaches capacity with adequate facilities are available

(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 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 Adequate length with water pipe line at JP Station is available, Watering is being done by commercial department

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

110(a)(iv) of Chg.Manual Rake testing rigs = 03 Nos and compressors = 02 Nos. are available

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 All coaches are air brake twin pipe type.

(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 .All coaches are fitted with enhanced capacity (75 t. Cap) screw couplings

13.3 Maintenance practices and system related requirements

110(c) of Chg.Manual

i) The integrity of the rakes to be

maintained.

110(c)(i) of Chg.Manual Being maintained.

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

110(c)(ii) of Chg.Manual Being done.

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

110(c)(iii) of Chg.Manual Being followed.

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 No such train is terminating at JP

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

110(c)(v) of Chg.Manual Being followed. The air flow meter is fitted in RTR

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

110(c)(vi) of Chg.Manual Being followed.

vii) Provision of audio visual alarm system on the locomotive

110(c)(vii) of Chg.Manual Does not pertain to coaching department

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

111(f)(i) of Chg.Manual Total 600 DCP type fire extinguishers are available in the depot Separate section for maintenance of fire extinguishers is available in sick Line premises. Fire extinguishers are being tested on Quarterly basis & refilled on yearly basis. Electronic weighing machine capacity 10 kg. is available. Adequate spares i.e. flexible pipes, caps, cartridges cylinders are available. The vessels are being given Hydraulic testing on three years basis

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

Coach type Nos of FE’s

Each Break Van 2 nos

Each AC coach 2 nos

Each Pantry car 4 nos

Each Generator van

2 nos

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

Fire extinguishers are being provided as per prescribed quantity in all trains. Train no. 19708 JP- BDTS was checked on 04-04-12 at platform no 5, FE-2 Nos. in SLR, PC-4 Nos. and in AC coach Two Nos. each was in OK condition.

15. Similarly, other brake van equipment, which Mechanical Train Examining staff is responsible to supply, should be provided according to the

111(g)(i) of Chg.Manual Fire extinguishers, wooden wedges and palm end couplings are being provided



instructions of each Railway. Portable control telephones, portable train lighting equipments, portable fire extinguisher, wooden wedges/skids and stretcher are to be provided.

in all primary trains. Other mentioned equipments pertain to other departments

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 Watering is being attended by commercial staff at JP.

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 Proper DRS cards are not being maintained. Deficiencies are being recorded on arrival and jointly signed by TXR and RPF staff. However it is not being jointly signed by Electrical staff.

(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 Deficiencies are not being

recorded of secondary and

terminal trains.(Other base

depots trains)

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 Computers are available in washing line and coach history cards are being maintained in computers but not compatible with the programme of the coaching work shop

(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 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 the Railway and as per Appendix F of Chg.Manual

113(a) of Chg.Manual Being followed.

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

113(b) of Chg.Manual Being followed.

19.3 Brake system maintenance Air brake system (Bogie mounted and underframe mounted):

Attention as detailed in para 113 ( c) is being given during primary /secondary attention of a rake.

113(c) of Chg.Manual Being followed

19.4 In addition to above the following items of work should be attended during the maintenance schedule examination: * under frames * bogie frames

113 (d) of Chg.Manual Axle boxes and springs are being cleaned during trip schedule with cotton waste. All under gear components are being examined and repaired as per IRCA conference rules. Knowledge



* 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.

of staff and supervisors regarding S marked rejectable defects was found satisfactory during sample check(Sh. R.C. Rajora SSE/SL and Sh. Dinesh Kumar, Tech-I on 05.04.12). However, the IRCA conference rule Pt-IV was issued in 2003 and needs to be updated in view of change of rolling stock.

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

Rajdhani and Shatabdi trains are not based at JP. However, dash pot oil is being checked on monthly basis in other trains.

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

113(e)(ii) of Chg.Manual Being followed. Wheel Tyre defect gauges, duly calibrated from RCF/KXH, are available at washing line and sick line.

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 Piston strokes and SAB dimensions “A” & “e” (SAB available in two coaches only) are being checked and recorded.

19.6 The following coach body components and fittings should be specially checked and attended to

113 (f) of Chg.Manual

i) Doors should be properly secured with the hinges/pivots and should not be grazing with floor or door sill plates.

113(f)(i) of Chg.Manual Being ensured. Train no 19708 JP-BDTS was checked on 04-04-12 and found all the doors in proper working order.

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

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

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

v) Window shutters should neither be tight nor loose

113(f)(v) of Chg.Manual Being ensured

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

vii) Window frame 113(f)(vii) of Chg.Manual Being checked

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

113(f)(viii) of Chg.Manual Being attended



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

113(f)(x) of Chg.Manual Being attended

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 Being attended

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

113(f)(xii) of Chg.Manual As per annexure 1.2, DRS record is not being maintained. However, deficiencies are being recorded and are being made good. However, magazine pockets, tumbler holders and snack tables are being recouped as per availability of items in CN coaches. In GS coaches of Train No. 59714 of 5-04-12, some of tube light covers were found deficient on arrival.

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 Record is being maintained on separate register of schedules A and B which does not cover item 3.3 of Annexure F of CAMTECH manual.

20. Schedule ‘A’ Examination 114 of Chg.Manual

i. Schedule `A' is required to be given every month + 3 days at the nominated primary maintenance depot within the normal primary maintenance time on a washing/pit line in a rake.

114 (a) of Chg.Manual Being done on washing line

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

114(b) of Chg.Manual Being done on washing line

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

114(c) of Chg.Manual Record is being maintained on separate register which does not cover item 1.1, 2, 4.4.8, 4.4.10 & 9.5 of Annexure F of CAMTECH manual.

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 Being done.

ii. The specified items of work should be attended.

115(b) of Record is being maintained on separate register which does not cover item 3.3 of Annexure F of CAMTECH manual.



iii. Brake system maintenance

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

Chg.Manual Being attended

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 Being attended

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

c. Thorough inspection and repairs of brake gear components.

115(b)(iv) of Chg.Manual Being attended

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

115(b)(v) of Chg.Manual Turn under and trough floors are being visually checked

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

115(b)(vi) of Chg.Manual Being attended.

22. IOH attention

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

22.1 Periodicity of IOH attention:

Coach Category

Periodicity

New coach at interval of 12 months in Depot

Rajdhani Satabdi (Conv)

at interval of 9 months in workshop

Mail / Express at interval of 9

months in depot

Passenger at interval of 9

months in depot

Other OCVs at interval of 12 months in depot

Tolerance for IOH may be kept as + 30/-0 days. Maintenance activities to be carried out during schedules should be as per Appendix-F & G. For IOH attention of newly built coaches, guidelines as circulated vide RB’s letter no. 2007/M ( C)/141/1 dtd 06.08.09

117(i) of Chg. Manual and correction slip 5 for coaching maintenance manual issued in 2008

IOH repairs are being carried out in sick line. Adequate facilities for IOH of coaches are available in sick Line. List attached as per Annexure-I

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

Being followed

22.3 Brake system : ‘C’ schedule

maintenance (IOH) as per para 426 of air brake chapter.

117(a)(i) of Chg.Manual Brake system is being tested of the coaches by SCTR. 02 SCTR are available in working order.

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

117(a)(vii) of Chg.Manual Dirt collector filter is being cleaned by compressed air and kerosene.

22.5 Other assemblies maintenance

All items of Schedule `B' 117(a)(i) of Chg.Manual All items of schedule ‘B’ are

being attended during IOH in sick line.



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 The bogie sets are being received from shops’ & changed during IOH.

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

117(a)(iii) of Chg.Manual Touch up of painting is being carried out.

22.8 Polishing of the polished surfaces. 117(a)(iv) of Chg.Manual Being Attended 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 Complete over hauled bogie (including shock absorbers) is being provided during IOH as received from Ajmer workshop. Adequate spare shock absorbers are available in depot.

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 Being done

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

117(a)(vii) of Chg.Manual Being done

22.12 Thorough checking and full repairs of all window shutters, safety catches, safety latches, staples and hasps of compartment, lavatory,

117(a)(viii) of Chg.Manual Being done

22.13 Thorough checking and repairs of UIC vestibules, their rubber flanges metal frames, doors, fall plate, locking gear, etc., for ease of operation and safety .

117(a)(ix) of Chg.Manual Being done

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

117(a)(x) of Chg.Manual Being attended and adequate quantity of PVC flooring is available

22.15 Engineer (C&W) of Primary Coaching Maintenance Depots should be fully familiar with the vulnerable areas of ICF coaches for corrosion, viz., sole bar at doorways, lavatories and adjoining areas, corridor sides - more so in case of those SLRs which are used for Fish, Salt, etc. For facilitating inspection of sole bars even spaced elongated holes of (215x127 mm) are already provided in the turn unders.

117 (d) of Chg.Manual Being followed.

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 Pockets between sole bars and turn under are being thoroughly cleaned, using compressed air and banister brush.

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 Design of floor has been changed (without drain holes) in new coaches fitted with stainless steel trough floor (most of the coaches are new ones). However, in old design



coaches it is being ensured.

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 Record of Schedule A, B and IOH attention are being maintained. However, record of ‘A’ & ‘B’ schedule is not as per CAMTECH 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 Not applicable as no such coaches are being homed at JP

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

118(c) of Chg.Manual Pertain to workshop

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.

Washing of linen is on contract basis and storage is being managed by JP depot. However distribution of linen in trains is being done by electrical staff.

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

Being done by SSE/Linen on quarterly basis.

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.

Being checked by SSE/Linen

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

Being followed. Inspections and payment, after recovery, is being dealt by JP division.

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

Buffer stock of 2 days is available.

ii.(e) Life of linen is adhered to: Bed sheets : 12 months for khadi, 24 months for poly vastra Pillow cover/face towel : 9 months Pillow : 24 months Blanket : 48 months

Being followed.

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

Committee has been nominated by DRM – Sr. DME/C&W, Sr. DFM/DFM & Sr. DCM/DCM

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

Being followed.

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

Being analysed at depot and divisional level. Corrective and preventive action is being taken accordingly.

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

No system exists



guidelines

24. Pest / Rodent Control

i. Comprehensive contract covering pest / rodent control in coaches and rodent control in pit lines / coaching depot yards awarded for 3 years under two packet system

Board’s letter No.2010(M)/C/141/7 Vol.IV dt.21.12.2010

03 yrs. Contract- M-442/3/Disinfestation Vol-III, under two packet system has been awarded to M/s Shatabdi pest control, Ratlam

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

All primary coaches have been covered under the contract.

iii. Minimum frequency of pest control treatment is adhered to : AC coaches / Pantry cars : Fortnightly, Reserved Non-AC coaches : Fortnightly in first 3 months, monthly thereafter, Unreserved Non-AC coaches : Bi-monthly Maximum tolerance +7 days, on account of operational exigencies, disturbance of rake links, etc.

Minimum frequency is being adhered to in the existing contract.

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

Branded chemicals as specified in the contract i.e. approved by Central Insecticide Board/Delhi are being used.

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.

Being followed

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

Being done by authorized agency - M/s Shatabadi Pest Control, Ratlam

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

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

Being done.

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

Stickers are being pasted in corridor near toilet but next due date is not being mentioned.

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

Though efforts are being made to detach Pantry cars once in a month but detachment depends on availability of spare stocks.

xi. Broad methodology for measuring the Being monitored



level of infestation of cockroaches and rodents and expected reduction over time is in place

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

The complaints are being analysed and corrective action is being taken.

25. Passenger amenities provided in

various types of coaches as specified

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

Being provided but magazine pockets and snack tables are being provided as per availability in CN coaches.

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

Not applicable

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

Para 1009 of Chg manual Being followed.

27.1 Wheel and axle Para 1009 a of Chg manual The rejection statement of last 03 yrs. is enclosed as Annexure C

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

Being checked by Tyre defect gauges and tread wear gauges. Gauges are being calibrated from RCF/KXH

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)

Being followed. Staff is well conversant with the limit of 50 mm.

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 sick line 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:

Being checked accordingly and proper records are being maintained. Copy of same is available as Annexure D

a) Shattered Rim

b) Spread Rim

c) Shelled Tread

d) Thermal Cracks

e) Heat checks

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.

Being followed. Copy of work order sent to Ajmer workshop is available as Annexure E.

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

All defective wheels are being sent to Ajmer workshops

27.2 Roller Bearing Axle Boxes Para 1009 b of Chg manual The rejection statement of last 03 yrs. is enclosed as



Annexure C.

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

no no no no

Defective wheels of such coaches are being sent to Ajmer workshop. The rejection statement of last 03 yrs. is enclosed as Annexure C One removed wheel with wing crack defect was seen in depot on 03.04.12.

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

No such cases were observed during checking in JP depot.

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.

Being followed. Defective wheels are being sent to Ajmer workshop to take 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

08 Nos. Laser temperature sensor devices are available at BG train Duty office. Checked and found in working order. 02 gangs in each roster are working at station. Spare nos. Are also available

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

Being followed

ii) If temperature is found above 800 C,

the affected coach will be detached. Staff is aware of criterion and

no such case was observed while checking the records

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

Being followed, record is available and no wheel set below 827 mm has been received from the workshop

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.

No such case was observed during checking of records

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

The new brake blocks are being procured by stores as per prescribed specs.

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

Being followed

29 Other items:

29.1 Changing of air brake hose pipe: Air brake hose pipe to be changed in every alternate POH attention.

Carriage Dte/RDSO letter no. MC /APB dtd 19.02.09

Pertains to Work shop

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

RDSO spec and STR Pertains to Work shop

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

No FAC coach is based at JP

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

Snack table in each bay. Mirrors in each bay Magazine holders on

partition wall Bottle and tumbler holder

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

Workshop is providing these amenities in new coaches, the amenities are not provided in old coaches and depot is advising workshop to provide during POH. However depot is making up the deficiencies if any during maintenance of new coaches equipped with such amenities.

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

Secondary Examination of T.No 12240/12239 is being done on pit line

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 and rolling- out examination is being carried out by train duty staff. Periodical super check by officers is being done but no record is available

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 as Duronto with chair car is not being maintained at JP

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

Being attended

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

No such coach based at JP

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.

RDSO/2009/CG/CMI-01, Sep’09

29.7 Analysis of sick marking and en-route coach detachment

i) Whether primary coach detachment is analysed and corrective & preventive action taken. Details of primary detachment for last 3 years to be collected.

Cause wise analysis of primary detachment is being maintained at Sick line. Copy is enclosed as Annexure C

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

Cause wise analysis of secondary detachment is being maintained. Copy is enclosed as Annexure F.

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.

No such case during last three years.

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.

Information at Annexure-I. JP is major depot having 553 coaches holding but no under floor wheel lathe is available.

30 Passenger satisfaction

30.1 OBHS & escorting of trains

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

Only 02 trains are covered under OBHS out of 08 trains, to be covered under OBHS

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

Nil

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

T.no. 19708/19707 and 19771/19772 are having OBHS

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

T.No. 12968,12970,12976, 12980,12940,19711 Are not covered under OBHS

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

Year wise PSI as per record is as under 2010-75.99, 2011-74.25. Cross Verification is been carried out by SSE/Ic.

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.

There is no documented system of feedback from passengers regarding cleanliness, Linen Quality and



pest infection of mail express trains. However, feedback is reflected in inspection reports of officers and Div C&W inspectors. Documented feedback regarding cleanliness is being collected of trains covered under OBHS and CTS. Copy of Performa are available as Annexure G & H

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.

Yes, the complaints are being analysed now and details of complaints with action taken for last 01 yr. is available as Annexure i

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.

There is no mechanized cleaning is being carried out at JP depot.

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

Not applicable due to upholstery coaches are not available.

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

Curtains are being changed on fortnightly basis and are being cleaned on contract basis.

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

02 month interval New contract

Blankets are being cleaned on monthly basis and record is been maintained.

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.

Cleaning of the washing line area is been carried out by contractor (M/s Dynamic Enterprises)

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

Leftover food is being collected by coach cleaning contractor and disposed at nominated bins.

c) Sustainable garbage collection and disposal system

Garbage is being collected in nominated bin and further disposed off by tractor outside railway boundary by contractor.

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

Water logging was observed in drain of washing line no. 3 and dirt collection was ok.

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

IOH/POH Fumigation/fogging of coaches is been carried out by contractor (M/s Shatabdi pest control) during IOH and off POH coaches.

f) Monitoring the functioning of OBHS and CTS scheme.

Surprise Inspection by OBHS sections supervisor incharge is being carried out



fortnightly. The OBHS section is available in sick line premises, consisting 01 JE and 02 Technician. The work of CTS contractor staff is being monitored by 02 gangs consisting of 03 technicians.

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.

Trains have been nominated by HQ under OYTS.

ii) Quality of linen supplied on trains:

a) Availability of clean and hygienic linen to passenger through washing quality, adequate quantity, replenishment with new linen on age / condition basis, use of washable blankets and appropriate quality of packing.

Adequate quantity of linen items is available in the depot. Quality of Washing is being monitored by SSEs /Officers and recorded as per Annexure I.

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

Mechanized laundry is situated at 4 Km Distance from Railway Station (M/s Rishi Ent.) The Detail of laundry is attached as Annexure K.

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

Linen Packet is consisting of two bed sheets, one pillow cover and one towel There is no system to monitor the “date of put in service of linen”.

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

N/A

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

Alsthom manual and OEM manuals

N/A



toilet system)

31.3 Wheel sets and CTRB attention at depot:

i) The wheels sets shall be inspected for the following conditions and action taken as indicated for each condition: Shattered Rim Spread Rim Shelled Tread Thermal Cracks Heat checks

Para 1009 a (iii) of chg manual

N/A

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

N/A

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

N/A

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 dt. 21.08.09

Rolling in and rolling out examination is being carried out. Rolling in lights are available on all the platforms on both sides. Two gangs of 08 technicians are provided on platform in each shift.08 LASER guns for staff use and one for supervisor available. However in washing line rolling in light is provided near washing line No. 3 only and not on washing line No. 1 side.

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

Not applicable

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.

N/A

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

N/A

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

N/A



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.

N/A

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

N/A

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

N/A

31.4 Phonic wheel/Speed censor OEM guidelines

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

N/A

ii) The clearance between the phonic wheel and speed sensor should be 0.9 to 1.4 mm in case of KB make WSP and 1 to 2mm in case of FTIL make WSP. This gap should be checked in quarterly schedule or whenever required.

N/A

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.

N/A

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

N/A

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

OEM guidelines N/A

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.

N/A

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

N/A

Junction box in broken/damaged condition.

N/A

31.7 Disc brake attention: OEM guidelines

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

N/A

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

N/A

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

N/A



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

CBC stock is not based for primary maintenance at JP

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

N/A


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

Mediu

m

Depot

Major

Depot

Observation

U/floor wheel lathe - - 1

NA. Wheels are being

sent to Ajmer

workshop.

Whiting jacks (5 Nos.) - 1 set 1 set 2 sets are available

EOT crane 20T - - 1 02 Nos. (35.5 T)

Coach Shunter - 1 2 Nil

Welding Plant 1 2 4 04 ( 02 BGSL, 02

BGRM )

Gas Cutting Equipment 1 2 2 02 (01 BGSL, 01

Spare)

Vacuum Exhauster 1 2 2 Nil

Air Compressor 30 cfm 1 2 2 02 Elc. + 01 Dsl.

Portable Vacuum Testing

Equipment - 1 1

Nil as no vacuum

stock is in holding

Portable Air Compressor - - 1 01

2T Tram beam hoist 1 1 2 Nil

Sewing machine - 1 1 01

Truck 10T - - 1 01

Light Coml. Vehicle 1 1 1 01 Bolero

Fork lift truck - - 1 01 ( 2T)

Lister truck 1 1 2 03 ( 02 Dsl + 01 Bat.)

Car Washer - 1 1 01 BGRM

Portable Trolley Light 2 4 Nil

Cotton waste soaking plant 1 1 1 NA

Wood cutting saw machine - 1 1 Nil

Hand shearing machine - 1 1 Nil

Portable Furnace 1 1 2 Nil


Description Minor

Depot

Mediu

m

Depot

Major

Depot

Observation

Centre Lathe - - 1 02

Bogie Manipulator - - 1 Nil

Ultrasonic Testing Apparatus 1 1 1 Nil

Tool post Grinder - 1 1 02 (01 BGSL, 01

BGRM)

Vacuum Cleaner 1 2 3 04

Pressure Jet Cleaner 1 2 4 05

Tools

a. Pneumatic Hand Tools

i. Grinder 1 1 2 Nil

ii. Drill 1 1 2 Nil

iii. Chipper / Buster - 1 2 Nil

iv. Riveter - - 1 Nil

b. Electric Power Tools

i. Pop Riveting Gun - 1 1 Nil

ii. Drill - 1 1 01

iii. Bolt Tightner - - 1 Nil

c. Hand Tools As required Nil

d. Test Bench

i. Water Tank Test Rig - 1 1 Nil

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

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

iv. Slack Adjuster Test Bench

- 1 1 NA

v. DV Test Bench - 1 1 NA

vi. Air brake single coach test rig

- 1 1 02 BGSL

e. Office Equipment

i. Computer system 1 1 1 07 PC’s + 05 Printer

ii. Plain Paper Copier 1 1 2 01 SSE

iii. Telefax 1 1 01 CDO


Annexure - II

Emergency materials required for platform (C&W) office

Sl. Items Required Observation

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

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

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

4 Draft link complete 2 sets 2 sets

5 Equalizing Stay rod with pins ( Non-

modif. & Modif.) 1 set each

1 set each

6 Anchor link with securing studs 1 set 1 set

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

8 Bolster suspension Link (Stirrup Link)

with Pins & Stones 2 sets 2 sets

9 Axle Box Face Cover (ICF) with securing

nuts & Pins 2 sets 2 sets

10 'O' Ring 2 nos. 2 nos.

11 Grease Servogen 4 kgs. 4 kgs.

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

13 Angle cock 2 nos. 2 nos.

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

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

16 Teflon Tape 1 no. 1 no.

17 Portable Air Pressure Gauge 1 no. 1 no.

18 Pressure Gauge BP & FP 2 each 2 each

19 BP & FP Air hose 2 each 2 each

20 Guard Emergency Application Valve 2 nos. 2 nos.

21 Wooden Plug (various sizes) 10 nos. 10 nos.

22 Wooden wedge 4 nos. 4 nos.

23 G.I. wire Adequ. Qt. Adequ. Qt.

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

25 Push cock 5 nos. 5 nos.

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

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

28 Hydraulic Jacks 2 sets 2 sets


Annexure – III

Details regarding coaching depot

Depot name and division: JP depot, JP division

1. Coach Holding

Mail/Expresses coaches with conventional coupling 540

Mail/Expresses coaches with CBC coupling Nil

Rajdhani/Shatabdi coaches (conv) Nil

LHB coaches (Rajdhani/Duronto) Nil

Shatabdi Coaches (conv) Nil

Shatabdi coaches (LHB) Nil

Passenger coaches Nil

OCV’s 13

Grand Total 553

2. Maintenance attention of at depot

PM of Mail/Expresses train with secondary attention at

other end

04 (12968/67, 70/69,

76/75, 19709/10)

PM of Mail/Expresses train with round trip attention at

other end

10

PM of passenger service with round trip attention at

other end

02 +02 (Weekly)

Total PM attention at depot: 20

Total SM attention at depot: 01

Total Round trip attention at depot: 13 trains P/F return

3. Pit line attention

24 coach pit with catwalk and high pressure water jet

facility/watering facility at per CAMTECH’s guidelines

03 Nos. Pit

(26 Coaches Each)

24 coach pit facility without catwalk Nil

Less than 24 coach pit facility with or without catwalk

(details to be collected)

Nil

Stabling line for round trip attention and stabling of

rakes:

Stabling line with 24 coach length facility

Stabling line with less than 24 coach facility

Nil

Compressed air with reservoir and air dryer/moisture

trap facility with test rig (RTR)

(02) With Drain

Facility for welding at Yard attention Yes ( 01 Portable)

Night maintenance facility with overhead/pit light as

per CAMTECH’s guidelines

Yes on all 03 pits

4. Sick line facility

Coach lifting facility with overhead crane Yes (02) 35/5T EOT


cranes

Coach lifting facility with JMP jack/hydraulic jack 02 Sets of Jamalpur

Jacks of 15 T capacity.

Total coach accommodation

With pit attention Without pit attention

10

06 Coach

04 each

Facility for compressed air with test rig (SCTR) 02 SCTR

Availability of hydrant water for overhead tank

attention

No

Welding facility Yes (02 Portable)

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

attention during night) as per CAMTECH’s guidelines. – Rolling in Lights (Parabolic

Focus Type are available on all PF on Both Sides.)

6. Availability of staff for coaching maintenance as per Yard stick. – 614 on roll against

sanction of 698.

7. Training status of supervisor and staff – There is no overdue training staff at JP depot.

8. Availability of critical/ safety stores and storage system. – There is no separate stores for

inflammable items such as paint, oil etc.

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

Annexure K

10.Bottlenecks / limitations of system / depot – There is no scope for extension of either

washing line or sick line. However holding is likely to be increased in future. There is no

stabling line available with RPC 4 facility.

11.Safety performance record – There is no enroute detachment of primary maintenance

coach and coach involved in accident/fire.

12. Performance of critical spare – Lower washer for axle box to PL No, 30010755 is

failing frequently


Annexure J

Instruction Chart of Fire extinguishers maintenance section


Marking the details on ready Fire Extinguishers

Annexure J

Ready Fire extinguisher kept in section


Defective Fire extinguishers

Annexure J

BP/FP gauge calibration stand


Chart showing Procedure of Magnaflux testing


Chart showing wheel defects

Quality Audit report Of Coaching Depot Jaipur, N W...

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