Quality Audit report Of Coaching Depot Lucknow, NE Rly ...

Quality Audit report

Of

Coaching Depot

Lucknow, NE Rly

Report no. 21/2012

APRIL 2012

(Audit is done by CRSE, ECR)

of 26 Coaching depot – LJN, NE Rly. April 2012

Quality audit Report of

Lucknow Jn. Coaching Depot, NE Railway

1.0 Introduction

As per instruction of Board vide letter No.2012/M(W)/814/5 dated 20.03.2012

and briefing by ED/QA/RDSO on 23.03.12, quality audit of LJN Coaching

Depot was done on 30th and 31st March, 2012. The team consisted of

CRSE/Chg., Dy.CME/CRW/HRK and 2 supervisors. At the outset all officers

and supervisors were briefed about the purpose of audit.

1.1 Audit team

Shri Hamid Akhtar, CRSE/Chg/ECR and Shri Janardan Prasad,

Dy.CME/CRWS/HRK,

1.2 Date of Audit 30.03.2012 and 31.03.2012

1.3 Escorting officers from depot

Shri Jairam Sandeep, Sr.DME/C&W/LJN and Shri D K Tiwary, CDO/LJN

1.4 Scope of audit

Entire coaching depot including washing Pit, Sick line, stores, wheel lathe,

Linen washing facilities, Depot records of various schedules, detachments,

DDR and Feedback.

2.0 Brief about LJN Coaching Depot

LJN Depot is at the Junction of NR and NER system. The Depot maintains 6

M/E, 1 passenger (Total 14 rakes) and 1 secondary maintenance apart from

platform return trains. It has 2 washing Pits 1 Sickline with all associated facilities

including Pit wheel lathe and 1 Linen washing facility.

3.0 STRENGTHS

3.1 The coaching depot though has only 242 coaches (bordering medium and

major depot), is spacious having 2 washing pits with 26 coach capacity,

adequate length of sick line (75x15 Mts. 4 coaches), adequate capacity service

building, 20/5 tonne capacity crane and pit wheel lathe. The surrounding area is

spacious and there is scope for capacity augmentation.


3.2 Development of Training Coach: a cut model of Coach depicting all under gear,

under slung and other details like CBC, turn under, etc has been made for

training purpose.

3.3 A useful gadget has been made for PVC fitment in the toilets. Systematic

fitment, using the gadget, shall reduce water seepage.

3.4 Rolling In Hut – An all weather Rolling-in Hut has been developed and

commissioned at Lucknow Junction.

3.5 Water Tank Testing Equipment: The testing equipment has been developed to

test the Water tanks under specified water hydraulic pressure of 0.34 kg/cm2 to

check the conformity of welded joints.

4.0 Weaknesses

4.1 High pressure jet is not being used on Primary rake reportedly due to non

supply of power. This is affecting cleaning of coaches.

4.2 One supervisor is managing under gear and coach body/interior examination,

this indicates that the practice is common.

4.3 Revised maintenance pattern JPO, certificates for other end facilities etc are

not available in the Depot for references.

4.4 Brake Blocks are not being changed in set of bogie (as checked from records)

4.5 A number of passenger amenity items (60% of magazine bags, bottle tumbler,

skirt moulding, PVC floor and trimming) were found deficient/damaged in the

rake.

4.6 No record of Temperature of Rolling-In of Primary Trains is maintained.

4.7 Fire extinguishers in AC coaches are being provided and maintained by

Electrical Department. The fire extinguishers were overdue testing.

4.8 Facilities for platform return attention such as High pressure pipeline, Flood

light for Rolling-in examination, and Inspection light along the track are not

available on LJN platform.

4.9 No illumination facility is available inside washing pit for under gear

examination. The Overhead light which is available is highly inadequate to

perform work.


4.10 History card is not being maintained in computer or even in register. No system

exists.

4.11 Due to non-availability of road transport for overhauled trolley for movement

from GKP workshop to LJN depot, due IOH coaches are being sent to GKP

coaching depot for changing of trolleys. This has led to practice of schedule ‘C’

attention to mail/express coaches (without using workshop overhauled trolleys).

4.12 There is no system of recording about, coaches being detached at the

secondary end or en-route. As such analysis and action is not being taken

systematically.

4.13 Availability of gauges and quality of supervisor needs improvement. Gauges for

buffer face plate, wearing piece (side bearer) were not available. Supervisors

were not aware of their importance. It would be appropriate to arrange training

in the depot for inspections.

4.14 Quality of linen washing is poor as calendaring machine has been out of order;

bleach is not being used in adequate concentration. Over-aged linen are not

being replaced as per stipulations. Supply of polyester quality of linen (for 1st

AC) is also poor. Stacking of linen is being done in shabby condition at floor.


Check sheet for Quality audit of LJN/NER 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 – 242

( M/E- 183, Pass-59)

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

Overdue Sch ‘A’ –Nil

(As per register checked)

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

rake

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

Overdue IOH - Nil


None of the coaches checked

were found overdue for any

preventive schedules. However,

09 coaches out of 23 coaches

checked on rake of Train no.

12533 had ‘C’ schedule

stencilled over their end panel in

place of IOH. On query, it was

told that since there was

shortage of bogie (overhauled)

from GKPS, coaches were given

‘C’ schedule on 6 month basis at

LJN itself. Out of a load of 23

coaches, 09 coaches had been

given ‘C’ sch., 11 recent POHed,

03 MLR return

6 Primary maintenance schedules are required

to be carried out by the base depots to which

coaches are allotted. In emergency, when

due to any reason coaches cannot reach

their base depots and primary maintenance

schedules become due, A & B schedules

should be undertaken by the carriage depots

where the coaches are available. ‘C’

schedule should be done at base depot.

112(b) of Chg.Manual A & B Schedules of coaches is

being undertaken in depot as per

their arising/periodicity

IOH- is not being done at depot

as road contract for

overhauled trolley is not in

place. Coaches are being sent to

GKP depot for change of trolley.



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

This is being ensured in

accordance to CAMTECH

manual and none of the primary

maintained train is allowed to

leave Pit with Brake power less

than 100%.

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

TXR staffs are examining all

coaches before dispatch to

destination.

8 Terminating Examination of Passenger

Trains – Rolling in examination.

107 b of Chg. Manual

Being done

8.1 Site shall provide unobstructed view of under

gear from both sides.

107 (b)(i)(a) of

Chg.Manual

Ok

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

Two staffs i.e. 01 from N/S & 01

from S/S carryout rolling-in-

examination and take action

accordingly in case of any

deficiency observed.

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

No records being maintained.

Although temp being taken (as

per CDO)

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

JPO is not available in the

depot

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

6 M/E primary trains run with

Round trip certificate. As per Sr

DME LJN, certification regarding

availability of other end facilities

has been ensured.

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 done wherever applicable

i.e. in UFMBC

ii) Brake blocks should be changed in bogie

sets only

-do- Not being done as per register

checked

iii) All missing passenger amenity fittings must

be replaced and the rake must be turned out

as ‘Zero-Missing-Fitting’ rake.

-do- Not being done in totality

iv) Intensive cleaning of coach toilets and

lavatory.

-do- Being done

v) Clear maintenance time of 6 hours on the pit

as per train schedule.

-do- Being followed religiously

vi) Provision of proper washing cum

maintenance pit line facility with adequate

testing equipment and high pressure jet

cleaning plant at primary end.

-do- The depot is spacious having

adequate washing pit capacity (2

* 26 coach length) of CAMTECH

design and SL capacity 3.5 8 75

meter, building, road and

surrounding space.



vii) Adequate gang strength with proper

supervision

-do- No. of supervisors less (one

supervisor was managing both

upper gear and under gear of

Pushpak rake.

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 followed

ii) The minimum infrastructure to be provided at

the platforms from where trains are returned

without secondary maintenance should be is

available

-do- No floodlight for Rolling in

examination

No inspection light along the

side of the track

No covered drains

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- No information available

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

No information available

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

Yes, it is being followed

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 Cleaning agents as advised vide

contract / tender awarded are

being adhered to e.g. Johnson

Diversy, Taski etc.

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

Rake protection using stop board

during maintenance at pit is

being done. Use of scotch blocks

is being done.

12.3 External cleaning /washing:

Check that guidelines as detailed in

CAMTECH manual are being followed.

109 (b) of

Chg.Manual

High pressure jet was not

being used reportedly due to

non supply of power.

12.4 Cleaning of Toilet:



109 (c) of

Chg.Manual

Toilets’ cleaning satisfactory.

Guidelines are being adhered to.

12.5 Internal cleaning of upper class AC and

sleeper coaches:



109 (d) of

Chg.Manual

Being satisfactorily done.

Garbage collection followed by

dry sweeping is being done. Use

of dry vacuum cleaning not

being done.

12.6 Internal cleaning of GS, SLR:



109(e) of Chg.Manual Being done



12.7 Cleaning of buffers and screw couplings 109(f) of Chg.Manual Being done

(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 done

(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 done.

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

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

Hydrants with 6” header pipe

available on CAMTECH design

(iv) Availability of the prescribed air brake

maintenance and testing equipment

110(a)(iv) of

Chg.Manual

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

Available in all coaches

(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

75 T screw couplings available in

all coaches

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

For train no. 15011 (LJN-

Chandigarh Exp) 6 hrs time is not

possible due to non availability of

washing pit slot as per this train

timing. For other trains

maintenance time of 6hrs is

available.

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

Round Trip attention as per RPC

4 revised

v) Trains leakage rate to be maintained within

prescribed limits by using rake test rig.

110(c)(v) of

Chg.Manual

Being maintained strictly

vi) Provision of proportionate brake system on

the locomotive in good working order

110(c)(vi) of

Chg.Manual

Not checked

vii) Provision of audio visual alarm system on the

locomotive

110(c)(vii) of

Chg.Manual

Not checked

14 Fire extinguishers should be checked every 111(f)(i) of FEs supplied on board by C&W



three months and completely refilled after

one year.

Chg.Manual was found ok. However, FEs

supplied by electrical

department’s AC wing in AC

coaches of 12533/34 were

overdue for testing.

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 found

Each AC coach 2 nos found,

overdue for tesing

Each Pantry car 4 nos found

Each Generator

van

2 nos NA

RB’s letter no. 95/Sec

(spl)/75/1 dtd

30.05.97

DCP type fire extinguishers are

in use as per this norm.

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

Available in side SLR of the rake.

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 Nominated

17 Deficiency Rolling Stock (DRS) for Coaching

Stock

111(i) (i) of

(i) Railway should devise system for detecting

deficiencies. Reports of deficiencies/ defects

in Rolling Stock (DRS) reports in the

proforma given in Annexure 1.2, should be

prepared for each mail/express/passenger

originating train in duplicate by the Engineer

(C&W)/Electrical (TL) and should be signed

jointly with the RPF representatives.

Chg.Manual DRS is not being maintained in

proforma as given in CAMTECH

manual. However register for

upper gear is sent to platform

office & thereafter given to o/g

guard after joint signature of RPF

& C&W.

(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

Being done

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 Coach maintenance History

card is not 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

Coach maintenance History

card is not being maintained

by Depot

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

113(a) of Chg.Manual Being followed as per latest

maintenance schedule.



Mechanical Engineer of 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.

113(b) of Chg.Manual Interior cleaning satisfactory.

High pressure jet was not

being used for external

cleaning.

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 done

19.4 In addition to above the following items of

work should be attended during the

maintenance schedule examination:

* underframes

* bogie frames

* axle boxes

* springs.

These items should be wiped with wet

waste weaves or cotton waste as necessary

so as to facilitate examination. All under gear

components should then be examined and

repaired as necessary to ensure that there is

no `S' marked rejectable defect as

mentioned in Chapter IV of IRCA Conference

Rules.

113 (d) of

Chg.Manual

Being done

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

No Rajdhani rake available /

maintained in depot.

D/pot oiling is ensured & oil is

replenished as & when required

during schedules.

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 adhered to.

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

Coaches checked during sample

check had BMBCs.

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

Checked & found ok.

ii) Door latches and safety catches 113(f)(ii) of

Chg.Manual

Found intact.

iii) Door lock handles 113(f)(iii) of Working freely.



Chg.Manual

iv) Tower bolts 113(f)(iv) of

Chg.Manual

Available

v) Window shutters should neither be tight nor

loose

113(f)(v) of

Chg.Manual

Ok.

vi) Window shutter safety catches 113(f)(vi) of

Chg.Manual

Available

vii) Window frame 113(f)(vii) of

Chg.Manual

Ok.

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

Found ok.

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

Found cleaned.

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 Being maintained.

Separate registers for ‘B’ & ‘A’

schedules are in place & are

filled in on completion of work.

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

No coach of rake no.-01

12533/12534 found overdue for

‘A’ schedule when checked at

washing pit on 29/03/12.

ii. Brake system maintenance

Air brake system (bogie mounted)

A schedule maintenance as per air brake

chapter

114(b) of Chg.Manual Being done

iii. The specified items of work should be

attended during Schedule ‘A’ examination,

i.e. monthly examination:-

114(c) of Chg.Manual Found being done in accordance

to instructions laid done in

CAMTECH chg 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 Found ok.

Overdue – Nil.

ii. The specified items of work should be

attended.

115(b) of

iii. Brake system maintenance

Air brake system (Bogie mounted)

(i) Same as 'A' schedule

Chg.Manual Being done.

iv. Other assembly maintenance

Besides brake system other items should be

attended as given below:

115(b)(i) of

Chg.Manual

a. All items of Schedule`A' 115(b)(ii) of

Chg.Manual



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

Chg.Manual

Found done.

As per register maintained for the

purpose i.e. records 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

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

Upper gear attention of IOH is

done in depot.

For Trolley change the Coach is

being sent to GKP Coaching

depot. There are some cases of

Schedule C of M/E Coaches

due to shortage of overhauled

trolleys.

Rest as per norms.

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 done.

22.3 Brake system : ‘C’ schedule maintenance

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

117(a)(i) of

Chg.Manual

No coach was under ‘C’ sch/IOH

on dates. However as explained

this is being followed.

22.4 Thoroughly clean Dirt collector filter in

kerosene or replace on condition basis.

117(a)(vii) of

Chg.Manual

Dirt collector filter was not

available in depot stores, hence it

is inferred that this is not being

done in all cases.

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

Being ensured as per records



22.7 Touching up damaged paint of coaches on

outside as well as inside.

117(a)(iii) of

Chg.Manual

Is done as per requirement on

condition basis.

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

Are being sent to shop for repair

& return records checked &

found being done.

22.10 Thorough cleaning and removal of dust, rust,

dirt, etc., accumulated at the pillars through

the turn under holes, with coir brush and

compressed air.

117(a)(vi) of

Chg.Manual

Not in practice.

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

Is in practice.

Trimmer was seen stitching berth

rexine in 12533/34.

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 as reported

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 monitored by U/gear TXR.

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

Standard of supervisors poor as

it was evident during interaction

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

Being done during schedules.

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

Action being taken in accordance

to defects found during trip

schedule.

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

Records being maintained at

depot level.

22.17

For maintenance of coaches of Rajdhani/

Shatabdi Express Rakes, the instructions

given in RDSO Technical Pamphlet No. C-

118 (b) of

Chg.Manual

NA



7807 should be followed.

22.18 The IOH of Rajdhani/Shatabdi high speed

coaches should be carried out in workshops

118(c) of Chg.Manual NA

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.

It has been taken over from

commercial department w.e.f

01.01.2011.

ii.(a) Stock verification of linen should be carried

out on a quarterly basis

Board’s letter

No.2009/M(C)/165/6

dt.4.1.2010

It has been carried out recently

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.

Inspection of washed linen is

being done both at supervisor

and officer level in accordance to

laid down guidelines of Railway

board.

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

Suitable deductions based on

passenger complaints are been

made at CDO level.

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

days is available

Shortage of Polyester Khadi

linen

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

Overaged stock of Dec’10

found available.

ii.(f) Committee nominated by DRM for linen

condemnation on condition basis

Committee exists for linen

condemnation on condition basis

iii. Specified frequency of washing/dry cleaning

of blankets and other linen items is adhered

to

Blankets are washed on monthly

basis. No JPO/guidelines

available.

23.1 Passenger complaint on account of linen is

analysed and corrective & preventive action

is taken

Contractor is being penalised on

account of passenger complaints

regarding poor wash quality of

linen.

23.2 Feedback on linen quality is obtained

through coach attendant as per RB’s

guidelines

Passenger feedback is being

taken.

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

M/S Aaditya pest specialiser has

been doing pest and rodent

control in the depot i.e. separate

contract exists.

ii. All reserved (both AC and Non-AC) covered

under contract, unreserved coaches may

also be covered as per requirement of

Railways

Pest and rodent control in all AC

and NAC coaches is being

undertaken by the firm in

accordance to periodicity as per

guidelines.



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 and Pantry cars are treated

on fortnightly basis and other

NAC coaches on monthly basis.

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

concentration, dose specified

Solfac (20 ml per 5 litre per

coach)

v. Minimum frequency of rodent control

treatment is adhered to :

AC coaches / Pantry cars : during every

Primary maintenance,

Reserved Non-AC coaches : Weekly

Maximum tolerance +7 days, on account of

operational exigencies, disturbance of rake

links, etc.

Rodent control Box of decent

design is used inside A/c

coaches.

vi. Personnel trained by certified training

institutes deputed for pest/rodent control

Personnel carrying out

P/contract are not trained.

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

Not in practice as this

provision was not available in

old guidelines.

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

As per available records,

coaches in rake form are being

attended for pest control

ix. Stickers indication date of pest control and

next due date provided in doorway/toilet area

Found available.

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

Being done.

xi. Broad methodology for measuring the level

of infestation of cockroaches and rodents

and expected reduction over time is in place

Not available in old guidelines.

Depot relies on passenger

feedback or complaint registered

through control.

24.1 Passenger complaints on account of pest are

analysed and corrective action is taken.

Contractor is being penalised for

passenger complaints as per

records available.

25. Passenger amenities provided in various

types of coaches as specified

Board’s letter

No.2006/M(C)/141/26

dt.21.12.2006.

Rake of 12533/34 was checked

for availability of passenger

amenity fittings:

1. 60% snack table and

magazine bags found missing.

2. Push cock/gravity cocks found

available.

3. Soap dispensers found

available in AC coaches etc.

26. Infrastructure facilities – Standard

integrated modular pit line have unified

maintenance.

Appendix ‘E’ of

Coaching manual

CAMTECH report

No.CAMTECH/M/99/I

Available



nfra-washing line/1.1

27 Examination and repair practice in carriage

maintenance depot for wheel sets and roller

bearing

Para 1009 of Chg

manual

27.1 Wheel and axle Para 1009 a of Chg

manual

i) Wheel profile should be checked

with Tyre defect gauge to ensure the

profile dimensions are within the

permissible limits.

Wheel profile is being checked

using tyre defect gauge wherever

suspected.

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)

Information available with

examination staffs and TXR.

iii) Guidelines for wheel inspection in

open line depots (Ref RDSO CMIK003)

In addition to normal checks exercised on

wheel condition during primary/secondary

maintenance of coaches, a detailed

inspection of wheels should be done when

the coaches are received in sickline for

attention for either schedules or out of

course attention. The wheels sets shall be

inspected for the following conditions and

action taken as indicated for each condition:

It is being done in the sick line

during schedules in the depot.

Wheel sets are visually examined

for all known defects and

thereafter confirmation is made

by using tyre defect gauge.

a) Shattered Rim (i) In 2011 (i.e. from Jan to Dec)

28 coaches had been detached

on wheel account.

(ii) in 2012 (i.e. from Jan to Mar)

08 coaches have been detached.

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.

(i) Turning is done in depot itself.

(ii) 04 new wheel sets are

available in the depot.

v) No repairs, except wheel profiling of

wheel sets is permitted to be done in

the maintenance depot.

Except wheel profiling no other

repairs on wheel sets is being

done in the depot.

27.2 Roller Bearing Axle Boxes Para 1009 b of Chg

manual

Details not available in the depot.

This should be available in

workshop.

i) A coach should invariably be detached

from service for the following defects

i) Hot axle box

ii) Damaged axle box

iii) Damaged front or rear cover

iv) Seized roller bearing

v) Coach involved in accident,

derailment, fire, flood etc.

It is in practice.

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

Coaches don’t remain grounded

for a long period after receipt in

the depot from POH shop.



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.

It is in practice.

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

No records being maintained.

02 staffs i.e. 01 from N/S & 01

from S/S carryout temp

measurement. platform.

i) Temperature to be checked at axle box top

(crown) at front face of axle

Staffs questioned regarding

correct location for focussing

the non-contact thermometer

were found unaware of the

same.

ii) If temperature is found above 800 C, the

affected coach will be detached.

Information available.

27.4 Minimum permissible wheel diameter in ICF

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

Guidelines available.

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.

Guidelines available.

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

Being followed.

28.2 Maintenance of brake gear rigging should be

given as per guidelines circulated by

ED/Carriage /RDSO vide letter no. MC

/ICF/B/D dtd 03.07.09

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

NA

29.2 Fire retardant items are provided in coaches

as per RDSO specification.

RDSO spec and STR Fitment ex shop is being done.

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

29.4 Additional amenities / facilities in GSCN type

of coaches are provided as under:

Snack table in each bay.

RB letter no. 2004 / M

(C)/165/16 dtd

29.03.05

Deficiencies found in the rake no-

1 of 12533/34:

(i) Snack table-60% deficient



Mirrors in each bay

Magazine holders on partition wall

Bottle and tumbler holder

(ii) Magazine bags-60% deficient

(iii) Bottle holders- 50% deficient

29.5 Maintenance of Duronto express:

i) Pattern of maintenance for Duronto train as

being followed for Rajdhani trains with pit

examination at both end should also be

follwed.


(C)/141/2 dtd

25.08.09

NA

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.


(C)/141/2 dtd

25.08.09

NA

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.


(C)/141/2 dtd

26.07.11

NA

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

NA

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

NA

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.

NA

29.7 Analysis of sick marking and en-route coach

detachment

i) Whether primary coach detachment is


taken. Details of primary detachment for last

3 years to be collected.

Yes. Annexure 1

ii) Whether secondary detachment is being


taken. Details of secondary detachment for

last 3 years to be collected.

No data available

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

No data available



with investigation report.

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)

Facilities available as per CAMTECH

guidelines as detailed in annexure – I to be

observed.

Available.

30 Passenger satisfaction

30.1 OBHS & escorting of trains

Whether depot has provision of OBHS as per

RB policy guidelines.

Only one train i.e. 12533/34

(LKO-CSTM Pushpak Express

has been provided with OBHS

facility)

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.

01

iv) Nos of Mail/ Express train in which no staff

from depot and OBHS through contract have

been provided.

04

v) Average PSI for OBHS implemented rakes.

Whether systems to cross verify PSI in

OBHS provided train is existing.

Average PSI:

January’12 : 98.13

Feb’12 : 93.80

March’12 : 98.49

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.

Yes, suitable penalty wherever

applicable is being imposed on

contractors.

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.

Available and being analysed

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.

Yes Mechanised Coach cleaning

is outsourced and equipment

such as high pressure jet

cleaning m/c, dry and wet

vacuum cleaner, scrubber,

buffing m/c, industrial floor

scrubber and steam cleaning

were found in adequate nos.

30.5 Whether depot has facility for upholstery and

carpet cleaning either through in-house or

through contract. Efficacy of cleaning to be

observed.

Available

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

No

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.

Found satisfactory.

b) Action in respect of implementation of

systems of system for collection bagging and

disposal of leftover food from pantry cars and

coaches.

System of collection of garbage

together with bagging for OBHS

train exists

c) Sustainable garbage collection and disposal

system

Dustbins are available along the

pit for garbage collection.

d) Functional and efficient drainage to avoid

water logging and dirt collection

Available

e) Periodic fumigation of coaches and high

standards of cleanliness in washing lines

Not being done as it was not

available in the earlier

contract.

f) Monitoring the functioning of OBHS and CTS

scheme.

OBHS is being monitored

through passenger feedback

form and action is being taken

accordingly.

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.

System of OYTS exists.

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.

Washed linen quality was

found poor.

Calendaring press machine

was found out of order.

Stacking of washed linen was

found being done around dirty

floors.

b) Commissioning of mechanised laundries at

critical locations dealing with large quantity of

linens

Not available. However it is

being planned.

c) System of packaging, storage and servicing

of the linen to the passenger must be

streamlined.

Plain packets being used.

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

NA

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.

Alsthom manual and

OEM manuals

NA



Secondary vertical dampers

Yaw damper.

Secondary lateral damper

Primary and secondary springs

Disc brake attention

CDTS (Controlled discharge toilet system)

31.3 Wheel sets and CTRB attention at depot: NA

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

NA

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


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

Facility exists.

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.

NA

viii) Depot should not permit wheel sets with

flaking in service. Adequate spare wheel sets

are available in depot.

NA

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.

NA

x) Grease oozing out is checked during

attention at depot and corrective action is

taken accordingly.

NA



xi) Drain holes of control arm should be

regularly cleaned to prevent its choking.

NA

xii) Checking of mounting bolts of control arm is

being done during primary maintenance.

NA

31.4 Phonic wheel/Speed censor OEM guidelines NA

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.

NA

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.

NA

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.

NA

iv) Speed sensors’ cables should be properly

connected and should be without any

loose strands.

NA

31.5 Dump Valve

Proper Dump Valve connection and ensuring

that no dump valve leaks during brake

application.

OEM guidelines NA

31.6 Earthing Device OEM guidelines NA

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.

NA

Most of the earthing devices with correcting

wires/cables were missing.

NA

Junction box in broken/damaged condition. NA

31.7 Disc brake attention: OEM guidelines NA

i) Brake pads are renewed on condition basis

and adequate spare is available at depot

NA

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.

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

No CBC equipped coach is

available in the depot.

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

Attention to Side buffer of

coaching stock is being done in

accordance with laid down

procedures vide coaching

manual.


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

Depo

t

Mediu

m

Depot

Major

Depo

t

Observation

U/floor wheel lath - - 1 Available

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

Synchronising jacks

available (02 sets of 05

no. each)

EOT crane 20T - - 1 Available 20/5 T

Coach Shunter - 1 2 Available

Welding Plant 1 2 4 Available

Gas Cutting Equipment 1 2 2 01 No. available

Vacuum Exhauster 1 2 2 Not available. Not

required

Air Compressor 30 cfm 1 2 2 01 Electric- 15m3/min

01 diesel- 10m3/min

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 Minitruck-01

Light Coml. Vehicle 1 1 1 Minitruck-01

Fork lift truck - - 1 02

Lister truck 1 1 2 01

Car Washer - 1 1 NIL

Portable Trolley Light 2 4 Not available

Cotton waste soaking plant 1 1 1 Not available. Not

required

Wood cutting saw machine - 1 1 NIL

Hand shearing machine - 1 1 NIL

Portable Furnace 1 1 2 NIL

Centre Lath - - 1 Available

Bogie Manipulator - - 1 Not available

Ultrasonic Testing Apparatus 1 1 1 NIL

Tool post Grinder - 1 1 NIL

Vacuum Cleaner 1 2 3 01

Pressure Jet Cleaner

1 2 4

02


Description

Minor

Depo

t

Mediu

m

Depot

Major

Depo

t

Observation

Tools

Pneumatic Hand Tools

Grinder 1 1 2 Available

Drill 1 1 2 Available

Chipper / Buster - 1 2 Not available

Riveter - - 1 Not available

Electric Power Tools

Pop Riveting Gun - 1 1 Available

Drill - 1 1 Available

Bolt Tightner - - 1 Available

Hand Tools As required

Test Bench

Water Tank Test Rig - 1 1 Available

D.A. Valve Test Bench - 1 1 NA

Vac. Cyl. Test Bench - 1 1 NA

Slack Adjuster Test Bench - 1 1 Not available

DV Test Bench - 1 1 Not available

Air brake single coach test rig - 1 1 02 nos

Office Equipment

Computer system 1 1 1 04 nos.

Plain Paper Copier 1 1 2 01 no.

Telefax 1 1 01 no.


Annexure - II

Emergency materials required for platform (C&W) office

SN Items Required Observation

1 Screw Coupling complete ( 75 t ) 1 no. Not available

2 Draw Hook ( ICF- Enhanced capacity) 1no. Not available

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

4 Draft link complete 2 sets NIL

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

(01 13 T

01 16 T) pins

deficient

6 Anchor link with securing studs 1 set NIL

7 Truss Bar Hanger with Pins & Cotters 2 sets Available

8 Bolster suspension Link (Stirrup Link) with Pins &

Stones 2 sets

01 available

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

Pins 2 sets

Not available

10 'O' Ring 2 nos. NIL

11 Grease Servogen 4 kgs. NIL

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

13 Angle cock 2 nos. NIL

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

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. Available

21 Wooden Plug (various sizes) 10 nos. 02 nos

22 Wooden wedge 4 nos. 02 nos

23 G.I. wire Adequ. Qt. Available

24 Buffer bolts (20x120 mm.) 8 nos. 04 nos

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 01 no.


Annexure - III

Depot name and division: LJN depot of Lucknow (NER) division

1. Coach Holding

Mail/Expresses coaches with conventional coupling 183

Mail/Expresses coaches with CBC coupling -

Rajdhani/Shatabdi coaches (conv) -

LHB coaches (Rajdhani/Duronto) -

Shatabdi Coaches (conv) -

Shatabdi coaches (LHB) -

Passenger coaches 59

OCV’s -

Grand Total 242

2. Maintenance attention of at depot

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

PM of Mail/Expresses train with round trip attention at other end 4 pairs (M/E)

PM of passenger service with round trip attention at other end 1 pair

Total PM attention at depot: 5 pairs= 14 rakes

Total SM attention at depot: 1 weekly

Total Round trip attention at depot: 11 trains daily at station

3. Pit line attention

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

facility at per CAMTECH’s guidelines Two pits with catwalk each

26 Coach capacity

Cleaning work outsourced

who as per contract, have

high pressure jet M/C, but

was not being used due to

non availability of power

24 coach pit facility with catwalk • Two pits with catwalk each 26

Coach capacity

Less than 24 coach pit facility with or without catwalk 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

Round Trip attention is being

given at platform itself.

3 stabling lines of 24 Coach

length available

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

rig (RTR) 2 nos. (1 electric and 1

Diesel) available with drier

Facility for welding at Yard attention Available for Pit, Sick Line and

Yard (portable)

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

guidelines

No light in pit, overhead light

lesser than required

4. Sick line facility

Coach lifting facility with overhead crane 20/5 Tonne Crane available

Coach lifting facility with JMP jack/hydraulic jack 2 sets available

Total coach accommodation

With pit attention Without pit attention

3 with Pit, 1 without Pit

Total- 4

Facility for compressed air with test rig (SCTR) Available

Availability of hydrant water for overhead tank attention Available

Welding facility Available portable as well as

supply line


5 Facility for rolling-in/rolling-out examination with adequate

lighting arrangement (for attention during night) as per

CAMTECH’s guidelines

Available but without flood light

6 Availability of staff for coaching maintenance as per Yard

stick Total as per zero based review

: 442

Sanction available- 270

Men on Roll : 250

7 Training status of supervisor and staff ( overdue training to be

observed and recorded)

Nil

8 Availability of critical/ safety stores and storage system Adequate spare available

9 Availability of coaches as per rake link with maintenance

spare

FACCW only one spare which is

being extended for POH

10 Bottlenecks / limitations of system / depot Staff shortage especially for

Linen mgt As linen

transportation is with limited

staff, while distribution in train is

by various agencies like

commercial, Electrical & even

C&W staff

Excessive theft of folding table

and other passenger safety

items

11 Safety performance record Derailment – Nil in last 3 years

Enroute detachment – Nil in

last 3 years

12 Performance of critical spare No system of communication

about Trial items Coach wise

by workshop. However this has

just started since Dec’11

Door Closure & AC 1 cabin

door locking arrangement

getting defective frequently

Quality Audit report Of Coaching Depot Lucknow, NE Rly ...

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