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Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
Government of India Ministry of Railways
Draft Report on
Infrastructural Facilities for Maintenance of LHB Coaches in Open Line
CAMTECH/2016/M/LHB-INFRA/Open-line/1.0 May – 2016
(For official use only)
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
Draft Report on
Infrastructural Facilities for Maintenance of LHB Coaches in
Open Line
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
Preface
At present, Indian Railways has a large holding of LHB type Coaches and also
increasing day to day due to better features and efficiency than ICF/RCF coaches.
There is need a change in infrastructure of Coaching depots to efficient and proper
maintenance of LHB Coaches for better performance and passenger safety.
This Report is prepared with the objective to provide informative technical details
on Infrastructure for LHB Coach maintenance for the guidance of Mechanical
engineers involved in maintenance of Coaching stock. It covers the constructional
features of pit line, lay out drawing of pit line without cat walk & with Automatic
coach washing plant, M&Ps required, Tools and equipments, flooring, EOT cranes
& type of sheds and its length etc..
This Report does not supersede any existing instructions from Railway Board,
RDSO & Zonal Railways and the provisions of IRWM, BIS codes & reports on the
subject. This Report is not statutory and contents are only for the purpose of
guidance. Most of the data & information mentioned herein are available in DMRC
and Coaching Depots on IR.
We welcome any suggestions from our readers for further improvement.
CAMTECH/Gwalior (K.P.Yadav)
Date : 02.05.2016 Director/Mech.
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
Contents
S.N Description Page No.
1. Objectives 1
2.
New design of pit line without catwalk and with ACWP
(Automatic Coach Washing Plant) with water recycling
treatment plant
1
3. Twin depth pit line 3
4. Modern equipments 3
5. Other facilities 3
6. Coaching Depot Layout for LHB 3
7. Data/details of layout of coaching complex 5
8. Features of maintenance bay 7
9. Features of maintenance bay
(pit line without catwalk without shed)
8
10. Features of Maintenance bay (Pit line with side catwalk
and without shed)
9
11. A view of pit line at DMRC on steel pillars: 10
12. Maintenance bay showing ramp, stairs & pillars: 11
13. Service room & space for vehicle & machinery: 12
14. Features of IOH depot (maintenance sick line): 13
15. Maintenance sick-line for LHB 14
16. Details of infrastructure facilities proposed for
primary maintenance depot (LHB coaches EOG)
15
17. Some modern equipments 30
18. Automated Wheel Diagnostic System (WDS) 30
19. Mobile lifting platform 33
20. Coach Lifting System 34
21. Wheel Changing System 35
22. Automatic in-motion train washing system (ACWP) 36
23. Layout and construction of automatic coach washing
plant
38
24. Process of coach cleaning and washing in different stages 41
25. Water recycling treatment plant. 45
26. Internal coach cleaning machine 47
27. Transportation Codes for LHB Coaches 48
28. Suggestions given by Zonal Railways during seminar on
21.07.2014 & 20.07.2015
49
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
ISSUE OF CORRECTION SLIPS
The correction slips to be issued in future for this handbook will be
numbered as follows:
CAMTECH/2016/M/LHB INFRA/Open line/1.0/CS. # XX date
...………….......
Where “XX” is the serial number of the concerned correction slip
(starting from 01 onwards).
CORRECTION SLIPS ISSUED
Sr. No. of
C.Slip
Date of
issue
Page no. and Item No.
modified
Remarks
CAMTECH/2016/M/LHB INFRA/Open line/1.0 1
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
1.0 OBJECTIVES:
Railway Board vide their minutes of the meeting for “Review of IOH/ POH
periodicity of coaches and performance review of LHB coaches” held in
Railway Board on 06.03.2014, No. 2007/M©/141/1 dated 12.03.14 under
item “B” and S. No. 14 for performance review of LHB coaches and other
issues directed CAMTECH to evolve a design of pit line with pre-fab.
constructions for expeditious implementation of projects. In addition to this,
need to construct a catwalk should also be re examined as pit lines without
catwalks also have advantages of more open space, easy and speedy
construction and are economical as well.
2.0 NEW DESIGN OF PRE-FABRICATED PITLINE WITHOUT
CATWALK AND WITH ACWP (AUTOMATIC COACH WASHING
PLANT & WATER RECYCLING PLANT)
Previously a 3-Tier system for coach maintenance was adopted by Indian
Railway on the basis of recommendations made by CAMTECH and
approved by Railway Board vide their letter No. 95/M©/165/11 dated
09.08.1999. In three tier system, the provision of catwalk was made for
washing/ cleaning operation of coaches during maintenance. During
finalisation of report, the provision of automatic coach washing plants at
maintenance depot was examined but, at that time, Indian Railways were
still in the process of laying these plants at few locations. It was decided
that as Railways as become fully confident with their design, performance
and sources of supply and automatic plants get proven in service, the above
arrangement may be reviewed suitably in order to explore the possibility of
having pit lines without catwalks.
In catwalk less design, for changing destination boards and window glass
cleaning, adequate number of movable trolleys/forklifts with suitable
attachment may be required. The requirement of water pipeline for coach
washing may also be reviewed in such cases.
As discussed in 12th CMG at Guwahati & CME‟s conference at Mumbai
and Shimla, it is felt by some of the Railways that the activities to be carried
out on a catwalk can be undertaken with the help of alternative means such
as mobile platforms, listers etc and therefore pit line design should be
without cat walk.
During the seminar at CAMTECH on 21.07.2014 on the issue, participants
were of the opinion that catwalk contributes little but only makes hindrance
in the free movement of man and material. Daylight is restricted and layout
CAMTECH/2016/M/LHB INFRA/1.0 2
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
makes clumsy. A new design of pit line without catwalk should, therefore, be
developed or Prefab casted catwalk with longer span may be provided.
ACWP with water recycling plant has been considered necessary for outside
cleaning of the coaches. This will reduce the efforts and time taken at the pitline
considerably. It will also improve the quality of the cleaning of the coaches. This
will ensure reduction in water consumption and wetness in the pitline. It has been
noticed that coach washing plants which are in use on Indian Railways are not
working properly due to various reasons. It is, therefore, proposed that a washing
plant of a specification equivalent to one available at PA coaching depot should
be provided.
A unified pitline for internal cleaning of coaches/examination and repair has been
considered in place of separate facilities for internal cleaning of coaches and
repair/examination of coaches. It has been noticed that if separate facilities are
provided, the time taken in shunting is 1-2 hours and thus the cycle time increases
considerably. The very purpose of this exercise i.e. to reduce the maintenance
time gets defeated. Further, since ACWP has been provided, the coach washing
will anyway be done at the entry point of the pitline, therefore, spillage of water
on pitline will be reduced to a great extent. This will serve the purpose of keeping
the pit dry to a great extent.
2.1 Merits and Demerits of Catwalk
SN Disadvantages of Catwalk Advantages of without Catwalk
01 Clumsy lay out Less clumsy lay out
02 Day Light is restricted Plenty of daylight is available
03 Cross movement is also restricted Easy movement of maintenance staff
2.2 Unified pit line: The unified pit line should be as per RDSO‟s drawing number
RDSO/M-00006/R1&R2 revised in October-2011(This Drawing is fit for entry of
Locomotive with 30 kmph.) or CAMTECH‟s report no. CAMTECH.M.Infra.99/1.0
(This Drawing is unfit for entry of Locomotive.) depending upon whether loco
movement is required or not on the pit line.
2.3 ACWP: Automatic coaches wash plant as per COFMOW‟s specification number
COFMOW/IR/M-CWP/2010 or latest.
2.4 WATER RECYCLING PLANT: Water conservation has become need of the hour
due to finite source of supply of water due to which water level is depleting
continuously. The water recycling in Railway coaching depots may help in conservation
of water. The NCR has already installed water recycling treatment plant in ALD Division
and has reported satisfactory performance. Railway Board vide letter No.
2015/M©/135/2(3) dated 30.01.2015 has also communicated one letter to RDSO for
judging the performance.
CAMTECH/2016/M/LHB INFRA/1.0 3
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
3.0 Twin depth pit
In the existing pit, staff could not walk without bending. Therefore, to
avoid this difficulty, it has been proposed to provide twin pit. In this design
a pit of size 600 mm wide and 450 mm deep pit has been provided in centre
of the main pit for easy walking of the staff. This will also serve as drain to
the pit as a FRP/Metallic mesh has been provided as a covered on the deep
drain for this purpose.
4.0 Modern Equipments
To improve reliability, reduce maintenance time and to have state of art,
facilities for examination, repair and maintenance of coaches, following
modern equipment may be recommended by Railway Board:-
Automated Wheel Diagnostic System
Mobile Lifting Platform
Bogie/Car body lifting System
Waste removal system for Bio-Toilets/Vacuum Toilets
Automatic in-motion Train Washing System
Water recycling treatment plant
Bogie turn table.
5.0 Other Facilities
Other facilities such as boundary wall, pliable road throughout the coaching
depot, concrete flooring, service rooms, proper lighting and their accessories
have also been proposed.
6.0 Layout
6.1. The coaching depot is planned for 28 LHB coach length rake.
6.2 The coaching depot consists of
a) Automatic in-motion coach washing plant (ACWP)
b) Automated wheel diagnostic system (WDS)
c) Maintenance bay (Pit-line)
d) Maintenance Sick line (under covered shed)
e) Service rooms
f) Stabling line
g) Shunting neck
CAMTECH/2016/M/LHB INFRA/1.0 4
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
6.3 Sequence of operation
(a) Train entering into the coaching depot
(b) Outside train washing on automatic in motion coach washing plant
(c) Detection of wheel defect on automated wheel diagnostic system
(e) Placement of rake on maintenance bay for complete maintenance and
safety examination
(f) Pulling the rake in shunting neck
(g) Train going out of the coaching depot after complete maintenance
Ref: Sketch-01
CAMTECH/2016/M/LHB INFRA/1.0 5
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
7.0 Data/detail of layout of Coaching Complex
77..11 (a) Length of the Coaching Complex = 2104 m
(b) Width of the Coaching Complex = 120 m
77..22 (a) Thickness of boundary wall = 23 cm
(b) Height of boundary wall = 2 m
(c) Length of boundary wall = 4000 m
7.3 (a) Width of road = 5 m
(b) Length of road = 2285 m
7.4 (a) Total track length = 6 km
(b) Number of points and crossings = 9 sets
7.5 (a) Width of the maintenance bay = 14.49 m
(b) Length of the maintenance bay = 675 m
(c) Construction of the maintenance bay = as per drawing/detail
77..66 (a) Width of maintenance Sick line = 19.5 m
(b) Length of maintenance Sick line = 200 m
(c) Construction of maintenance Sick line = as per detail
7.7 (a) Width of Service rooms = 5m
(b) Construction of Service building = as per detail
7.8 (a) Width of sub-station rooms = 5 m
(b) Length of sub-station room =10 m
(c) Number of sub-station room= 2 nos
Ref: Sketch-01
CAMTECH/2016/M/LHB INFRA/1.0 6
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
CAMTECH/2016/M/LHB INFRA/1.0 7
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
8.0 Features of maintenance bay
8.1 Data/dimensions :
(a) Length of maintenance bay = 675 metres
(b) Width of maintenance bay = 14.49 metres
(c) Capacity = 2 rakes
8.2 The maintenance bay is meant for all safety checks, schedule and non
schedule maintenance of under gear and upper gear.
8.3. Main features of the maintenance bay are -
a. Broad and obstacle free pathways.
b. Under pit pathway below the rake/track.
c. Pit line on metallic (steel) pillars.
d. Ramp at both the sides to go from ground level to pathways.
e. Provision of stairs to go from ground level to pit pathway.
f. Provision of service rooms.
g. Provision of mobile lifting platform (for without catwalk).
h. Provision of compressed air pipe line.
i. Provision of overhead light.
j. Provision of under pit light.
k. Provision of 48V,110V, 230V ,440V cables and sockets
8.4 Other salient features:
a. To make the pathways obstacle free cables for the sockets are running
underground.
b. The under pit light are located such that they come under each bogie
of each coach.
NB : 1. The sketch of maintenance bay does not have structural and
foundation design of load bearing items.
2. Hence the dimensions shown may require changes due to design
considerations.
CAMTECH/2016/M/LHB INFRA/1.0 8
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
9.0 Features of maintenance bay (pit line without catwalk without shed)
9.1. Data/dimensions :
(a) Length of maintenance bay = 675 metres
(b) Width of maintenance bay = 14.49 metres
(c) Capacity = 2 rakes
CAMTECH/2016/M/LHB INFRA/1.0 9
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
10.0 Features of maintenance bay (pit line with side catwalk without shed)
10.1. Data/dimensions :
(a) Length of maintenance bay = 675 metres
(b) Width of maintenance bay = 14.19 metres
(c) Capacity = 2 rakes
Covering features of both pitline with catwalk and without catwalk
Note : The pit line is proposed on steel pillars of 500x500 size with a clear space
of 1000 mm between the pillars. The detail drawing to be prepared by the Zonal
Railways based on actual site conditions and necessity of loco movement.
CAMTECH/2016/M/LHB INFRA/1.0 10
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
11.0 A view of Pit line at DMRC on steel pillars:
CAMTECH/2016/M/LHB INFRA/1.0 11
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
12.0 Maintenance bay showing ramp, stairs & pillars:
Sket
ch N
o. 4
Prep
ared
By
CA
MT
EC
H/G
wal
ior
CAMTECH/2016/M/LHB INFRA/1.0 12
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
13.0 Service Room & Space for Vehicle & machinery:
3. A
ll ro
oms a
re fi
tted
with
stan
dard
ele
ctric
al fi
tting
s of
sui
tabl
e an
d ap
prop
riate
qua
ntity
and
qua
lity
SER
VIC
E R
OO
M A
ND
SPA
CE
FOR
VEC
HIL
ES A
ND
MA
CH
INER
IES
1. T
he s
ervi
ce ro
oms a
re lo
cate
d in
bet
wee
n m
aint
enan
ce b
ay a
nd m
aint
enan
ce w
orks
hop
serv
ing
at o
ne si
de to
mai
nt.b
ay a
nd a
t oth
er si
de to
mai
nt.w
orks
hop.
Exam
inat
ion
pit
Veh
icle
Spa
ce
2. A
ll ro
oms a
re h
avin
g do
ors,
win
dow
s an
d ra
cks e
tc o
f sta
ndar
d di
men
sion
s.
4. T
he sk
etch
doe
s not
hav
e st
ruct
ural
and
foun
datio
n de
tail
of th
e ro
oms.
2 55 2
Spac
e fo
r ser
vice
room
, veh
icle
and
mac
hine
s
Mai
nten
ance
Wor
ksho
p
Mai
nten
ance
Bay
30
Sket
ch N
o. 5
CA
MTE
CH
/Gw
alio
rPr
epar
ed B
y
CAMTECH/2016/M/LHB INFRA/1.0 13
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
14.0 Features of IOH Depot (Maintenance Sick Line):
1. Data/dimensions :
(i) Length of maintenance sick line = 200 metres
(ii) Width of maintenance sick line = 19.5 metres
(iii) Capacity = 2 lines
2. The IOH Depot (maintenance sick line) is meant for attending the unfit
coaches and for attending higher maintenance schedules of the coaches.
3. Main features of the maintenance sick line are:
a. Provision of 04 LHB coach length examination pit – One on each
line.
b. Provision of wheel profile lathe.
c. Provision of bogie/coach lifting system.
d. Provision of equipments like coach lifting jacks, material carrier,
fork lifter, hoist, bogie turn table.
e. Provision of service rooms, store and vehicle parking space.
f. Provision of wheel parking.
g. Provision of covered shed.
h. Provisions of electrical fitting, light, fan etc and electric supply to all
fixed and portable machines and equipments
NB : 1) The sketch of maintenance sick-line does not have structural and
foundation design of load bearing items.
2) Hence the dimensions shown may require minor changes due to
design considerations.
3) Big machineries like wheel lathe, coach lifting system etc should be
installed suitably.
Ref: Sketch No. 05 & 06
CAMTECH/2016/M/LHB INFRA/1.0 14
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
15.0 Maintenance Sick-line:
CAM
TECH
/Gwa
lior
Prep
ared
By
Sketc
h No.
6
CAMTECH/2016/M/LHB INFRA/1.0 15
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
16.0 DETAILS OF INFRASTRUCTURE FACILITIES PROPOSED FOR
PRIMARY MAINTENANCE DEPOT (EOG LHB Coaches)
A. Infrastructural Facilities & Building:-
S.N. ITEMS COACH HOLDING
0-50 51-100 101-250 251-500 501-1000
1. Covered shed (Sick Line) 1 1 1 1 1
2. Maintenance lines with pit (No. of lines
x No. of coaches)
1 x 2 1 x 2 2 x 2 2 x 4 2 x 6
3. Wheel line 1 1 1 1 1
4. Linen store room, size 5m x 15m
5. Battery room with battery beds Size 5m
x 10m
1 1 2 2 2
6. Room for storing cleaning equipment,
size 5m x 10m
1 1 1 1 1
7. Mech. item repair room with test
benches, size 5m x 10m (DV, Brake
cylinder, Bio-Toilet/CDTS etc.)
1 1 2 2 2
8. Mechanical millwright room, size 5m x
10 m
- 1 1 1 2
9. Computer room, size 5m x 5m - 1 1 1 1
10. Diesel engine overhaul shed with 5T
EOT crane (2 each)
1
12m
x
15m
1
12m x
25m
1
12m x
30m
1
12m x
45m
1
12m x
60m
11. Pantry equipment repair room, size 5m
x 10m
1 1 2 2 3
12. Power car equipment testing room with
suitable test benches, size 5m x 10m
1 1 2 2 3
13. Switch gear test room, size 5m x 10m 1 1 2 2 3
14. Fan/Light fittings repair room, size 5m
x 5m
1 1 2 2 3
CAMTECH/2016/M/LHB INFRA/1.0 16
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
S.N. ITEM COACH HOLDING
0-50 51-100 101-250 251-500 501-1000
15. Electric motor repair room, size 5m x
5m
1 1 2 2 3
16. RMPU Simulator training room, size
5m x 10m
1 1 1 1 1
17. Staff training room facilities including
projector, LCDTV, video camera, DVD
handycam & other modern teaching aids,
Size 5m x 10m
- 1 1 1 1
18. Radiator cleaning room with necessary
facilities, size 5m x 5m
- 1 2 2 2
19. Engine sub assemblies repair room with
repairing & calibration facilities, size
5m x 10m
1 1 2 2 2
20. Tool room with shelves and almirahs,
size 5m x 10m
1 1 2 2 2
21. FIP pump & injector repair room (AC)
with testing and caliberation facilities,
size 5m x 5m
1 1 2 2 3
22. Inductive load (500kW) testing room
with test benches, size 5m x 5m
1 1 1 1 1
23. Dynamo meter (500kW) test room with
suitable test benches
1 1 1 1 1
24. 50/60-kVA transformer repairing room
with testing facilities, size 5m x 10m
1 1 2 2 3
25. I.V. coupler/ HOG coupler# & ratchet
wheel repair room with test facilities,
size 5m x 5m
1 1 1 2 2
26. Main Store with Unit Exchange Spares
with material storing facility (size 5m x
10m) for Electrical & Mechanical
separately.
2 2 4 4 6
27. Shift/ Custody stores with material
storage facility (size 5mx5m) for
Electrical & Mechanical separately.
2 2 2 2 4
28. Scrap material room/shed of adequate
size as per requirement.
1 1 1 1 1
CAMTECH/2016/M/LHB INFRA/1.0 17
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
S.N. ITEM COACH HOLDING
0-50 51-100 101-250 251-500 501-1000
29. Storing facility for Lube, HSD,
Kerosene oil, size 5m x 5m
1 1 1 2 2
30. Storing facility for refrigerants, DA &
oxygen, Nitrogen, size 5m x 5m
1 1 1 2 2
31. Depot officers Gazetted room, size 5m
x 5m
-- 1 JS 1 SS 2
JS & SS
4
(1JA, 1SS,
2JS)
32. In charge/ SSEs/JEs office, size 5m x
5m
1 2 2 4 6
33. Establishment office, 5m x 10m - 1 1 1 1
34. PPIO office, size 5m x 5m -- 1 1 1 1
35. Material management office, size 5m x
5m
-- 1 1 1 1
36. Scooter & cycle stand of adequate size 1 1 1 1 1
37. Conference room of adequate, size 25m
x 10m
-- -- 1 1 1
38. Staff room with lockers size 5m x 10m 1 1 2 2 3
39. Staff room for ladies, size 5m x 5m 1 1 1 2 2
40. Separate toilets for gents and ladies. 2 2 4 4 6
41.
Electronic lab (AC) with all repair and
testing facilities
size 5m x 5m
-- 1 1 1 1
42. Staff Canteen of adequate size. - 1 1 1 1
43. Vehicle repair room, size 5m x 10m
44. Room for various meter testing and
calibrating facility, size 5m x 5m.
-- 1 1 1 1
# Applicable for HOG system
CAMTECH/2016/M/LHB INFRA/1.0 18
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
B. Mechanical (M&P) at Sickline
S.N. ITEM 0-50 51-100 101-250 251-500 501-1000
1. Automatic coach washing plant
(ACWP) with water recycling
- - - 1
1
2. Wheel diagnostic system (WDS) - - - 1 1
3. Coach lifting system - - 1 1 1
4. Wheel profile lathe 1 1 1 1 1
5. Synchronized electrically
operated Whiting Jacks of 15 T
capacity
2 2 4 6 8
6. Welding plant (portable) Single
phase 230 V 1 2 3 4 5
7. Welding plant (Stationary) 3 Ph.
440 V
- 1 2 2
3
8. Air compressor-350 cfm with air
dryer (Diesel) 1 1 1 2 2
9. Air compressor-350 cfm with air
dryer (Electric)
1 1 1 1
1
10. EOT crane 20/10T in
maintenance sick line
1 1 1 2 2
11. Floor scrubber 02 02 04 05 06
12. Dry & wet vacuum cleaner 02 02 04 05 06
13. Mobile jet cleaner 04 06 08 10 12
14. Drainage pump heavy duty 5HP
(Muck pump centrifugal)
1 1 1 2
2
15. Sewing machine 1 1 1 2 2
16. Portable pump 1 1 1 2 2
17. Gas welding-cutting set 1 2 3 4 5
18. Lathe machine, 1000mm between
centre complete including spares
and accessories with attachment
for precision grinding and tapering.
1 1 1 1 1
19. Bench vice 1 2 3 4 5
20. Medium sized electric motor
driven pillar drilling machine
complete.
1 1 2 2 2
21. Heavy-duty motor driven
pedestal grinder complete.
1 1 1 2 2
22. Portable electric motor driven
drill machine.
1 2 3 4 6
23. Portable electric motor driven
grinder.
1 1 2 4 5
CAMTECH/2016/M/LHB INFRA/1.0 19
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
S.N. ITEM 0-50 51-100 101-250 251-500 501-1000
24. Electric motor driven Winching
machine for movement of
coaches of suitable capacity
1 1 1 2 2
25. 46.7 Ltrs spare oxygen (7 m3
) gas
cylinders
2 2 3 4 6
26. 41 Ltrs spare Acetylene (5.5 m3
)
gas cylinders
2 2 3 4 6
27. Hand tools for coach maintenance
staff
As per
require
ment
As per
require
ment
As per
requirem
ent
As per
requirem
ent
As per
requireme
nt
28. Maintenance staff tool boxes
with tools.
For
each
tech.
For each
technici
an
For each
technicia
n
For each
technicia
n
For each
technician
29. Pipe bending machine for air
brake SS pipes
1 1 1 1 1
30. Inverter based AC/DC TIG
welding machine
1 1 1 1 2
31. Synergic pulse Tag welding
plants
2 4 6 8 10
32. Synergic Tag welding plant 1 1 2 2 2
33. Welding rectifier 1 1 1 1 1
34. Air plasma cutting machine 1 1 1 2 2
35. Pick & carry mobile crane 10
tonne
1 1 1 2 2
36. Hydraulic material carrying and
lifting system – For lowering and
carrying of CBC
1 1 1 2 2
37. Milling machine 36x8 Gear head - 1 1 1 1
38. Walk behind power vacuum
sweeper
- - 1 1 2
39. Pendulum action jig saw machine - - 1 1 1
40. Test bench for brake control panel 1 1 1 1 1
41. Square drive torque wrench 1”
male square drive for fastening of
Nuts and bolts of Bogie frame.
1 1 1 1 1
42. Hydraulic torque wrench – For
Nuts and bolts of Bogie frame
1 1 1 1 1
43. Torque wrench (ratchet) torque
38 Kg-m sq. drive ¾”
1 1 2 4 4
44. Torque wrench (ratchet) torque 3-
14 Kg-m sq. drive ½”
1 1 2 4 4
CAMTECH/2016/M/LHB INFRA/1.0 20
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
S.N. ITEM 0-50 51-100 101-250 251-500 501-1000
45. Torque wrench (ratchet) torque 7-
35 Kg-m sq. drive ½” and ¾”
1 1 2 4 4
46. Gauge for checking Bearing
Mounted End Play.
1 1 1 1 1
47. Bench end-play checking fixture. 1 1 1 1 1
48. Fixture for bearing lubrication 1 1 1 1 1
49. Spring testing machine for
Load/Deflection
1 1 1 1 1
50. Testing machine for Yaw
dampers.
1 1 1 1 1
51. Vernier dial calliper 0-300 mm 1 1 1 1 1
52. Vernier calliper 0 – 600 mm 1 1 1 1 1
53. Vernier Calliper 0-2000 mm- For
inspection of bogie frame
1 1 1 2 2
54. Vernier height gauge 18” 1 1 1 1 1
55. Vernier calliper (digital) 1 1 1 1 1
56. Micrometer digimatic range 125
to 150 mm
1 1 1 1 1
57. Micrometer digimatic range 150
to 200 mm
1 1 1 1 1
58. Digimatic inside micrometer
tubular range 175 to 200 mm
1 1 1 1 1
59. Inside micrometer range 175-225
mm
1 1 1 2 2
60. Digimatic inside micrometer
tubular range 200 to 225 mm
1 1 1 1 1
61. Dry film thickness measuring
equipment
1 1 1 1 1
62. Gloss meter 1 1 1 1 1
63. Surface roughness comparator 30
specimens
1 1 1 1 1
64. Bench pillar drilling machine 1 1 1 1 1
65. Portable hand drill machine 1 1 1 2 2
66. Tool cabinet As per
require
ment
As per
require
ment
As per
require
ment
As per
require
ment
As per
requirem
ent
67. Material handling crate --do-- --do-- --do-- ---do-- --do--
68. Cleaning sink As per
req.
As per
req.
As per
req.
As per
req.
As per
req.
CAMTECH/2016/M/LHB INFRA/1.0 21
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
S.N. ITEM 0-50 51-100 101-250 251-500 501-1000
69. Impact spanner --do-- --do-- --do-- ---do-- --do--
70. Pallet trolley --do-- --do-- --do-- ---do-- --do--
71. Feeler gauge --do-- --do-- --do-- ---do-- --do--
72. Allen key set as per list --do-- --do-- --do-- ---do-- --do--
73. One meter stainless steel scale --do-- --do-- --do-- ---do-- --do--
74. 12” stainless steel scale --do-- --do-- --do-- ---do-- --do--
75. Measuring taps 03 mtrs. --do-- --do-- --do-- ---do-- --do--
76. Steel rule --do-- --do-- --do-- ---do-- --do--
77. Heavy duty rechargeable torch --do-- --do-- --do-- ---do-- --do--
78. Trestle for stabling coach body --do-- --do-- --do-- ---do-- --do--
79. Press for pressing body wall --do-- --do-- --do-- ---do-- --do--
C. M&P and tools required at Pit line.
1. Tool kit (Torque wrenches, Allen keys, pliers, spanners set etc.)
2. High pressure jet cleaning machine.
3. Axle dia measurement gauge/micrometer.
4. GO/NO GO threads plug gauge for axle ends.
5. Parallelism checking tool for control arm.
6. Equipment for pneumatic System Functional Test.
7. Single car testing rig for air brake system.
8. Mounting/ dismounting tools for Anti roll bar bearing.
9. Mounting/ dismounting tools for Anti roll bar elastic joint.
10. Miner pad pressing Fixture
11. Inspection torches
12. Spiked hammers
13. Ball peen hammers
14. Goggles for inspection staff
15. Measuring tape
16. Measuring scale
17. Gas cutting plants
18. Multi-operator welding plants
19. Electrical angle grinders
20. Pneumatic hand grinders
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Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
D. Testing Facilities (Mechanical)
S.N. ITEM 0-50 51-100 101-250 251-500 501-1000
1. Air brake rake test rig 1 1 2 4 6
2. Single car test rig (SCTR) 1 1 2 4 6
3. Water tank test rig 1 1 1 1 1
4. Ultrasonic testing apparatus 1 1 1 1 1
5. DV test bench 1 1 1 1 1
6. Test facility for CDTS/Bio-Toilet 1 1 1 1 1
7. DP test facilities 1 1 1 1 1
8. WSP test feacilities 1 1 1 1 1
E. Material handling equipments
S.N. ITEM 0-50 51-100 101-250 251-500 501-1000
1. Fork lifter 3T 1 1 2 2 2
2. Fork lifter 1.5T 1 1 2 2 2
3. Lister 1.5T 1 2 4 6 8
4. Mobile lifting platform 2 4 6 10 12
5. Hydraulic pallet truck 01T
capacity
1 1 2 4 6
6. Lorry truck - 1 1 1 1
7. Pick up Van - 1 1 2 2
8. Push type/ Hand trolley 500 kg 2 2 4 6 6
9. Material van - 1 1 2 2
CAMTECH/2016/M/LHB INFRA/1.0 23
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
F. Safety Equipments
S.N. ITEM COACH HOLDING
0-50 51-100 101-250 251-500 501-1000
1. All workmen safety equipments such
as industrial helmets, hand gloves,
industrial shoes, masks, minor lamp
etc.
As per requirement
2. Fire extinguishers, water hydrants,
sand buckets with stand As per requirement
3. Safety belts As per requirement
4. FFiirrsstt aaiidd bbooxxeess As per requirement
G. Other facilities
NOTE: Facilities for the items which are likely to be offloaded to trade
should be provided judiciously to avoid wastage of resources.
S.N. ITEM COACH HOLDING
0-50 51-100 101-250 251-500 501-1000
1. Computer (PC) with printers to analysis
TL & AC failures & records and LAN
facility
2 4 6 8 10
2. Fax machine 1 1 1 1 1
3. Photo stat machine with Scanner 1 1 1 1 2
4. Walkie talkie sets/ Mobile sets/P &T
phones/ intercom and other
communication facilities
As per requirement
5. Water Cooler with purifier As per requirement
6. Storage racks, almirah, locker, furniture
etc As per requirement
7. Bins, container etc As per requirement
CAMTECH/2016/M/LHB INFRA/1.0 24
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
H. ELECTRICAL TOOLS, MACHINES & PLANTS
(Ref: CAMTECH Maintenance Manual for LHB Coaches Annexure-11.9 of Chapter 11)
The facilities mentioned below are bare minimum. However, if some facilities are
already available (either in mechanical or electrical sick line) only supplementing would be
necessary. Effort should always be made to complete both electrical and mechanical
maintenance in single placement of the rake.
I. REPAIRING & TESTING FACILITIES
S.N. ITEM COACH HOLDING
0-50 51-100 101-250 251-500 501-1000
1. Engine sub assemblies repairing &
calibration facilities
1 1 2 2 3
2. FIP pump & injector repairing, testing
and calibration facilities
1 1 2 2 3
3. I.V. coupler/ HOG coupler & ratchet
wheel repairing and testing facilities
1 1 1 2 2
4.
Filter cleaning arrangements with
blower & water sump for cleaning/
drying air filters
1 1 2 2 2
5. Radiator cleaning tank size 2W x 4L
x 2D (in meters).
-- 1 1 1 1
6. Microprocessor based Electronic card
reading and repairing facilities.
-- -- 1 1 1
7. HSD oil decantation facility with
pump for generator car shed of
suitable capacity.
-- 1 1 1 1
8. 500 kW load testing facility for power
car (Inductive/ Resistive)
1 1 2 2 2
9. Test bench for Diesel engine
(Dynamometer type)
1 1 2 2 2
10. Test bench for on load testing of
Alternator of power car
-- -- 1 1 1
11. Testing supply points 750V 3 phase At each coach length
12. Portable Step up transformer 415/750,
50/60kVA
1 1 2 2 4
CAMTECH/2016/M/LHB INFRA/1.0 25
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
S.N. ITEM COACH HOLDING
0-50 51-100 101-250 251-500 501-1000
13. Test bench for testing relays &
contactors
1 1 2 2 2
14. Power supply analyzer, oscilloscope
dual channel, storage type
1 1 2 2 2
15. Testing facility of RBC and
emergency battery charger
1 1 1 2 2
16. Mono-block pump testing facility 1 1 1 2 2
II. MACHINE & PLANT
S.N. ITEM COACH HOLDING
0-50 51-100 101-250 251-500 501-1000
1. Arial lifting platform for climbing on
roof of coach. 1 1 2 2 3
2. EOT crane 10T 1 1 2 2 4
3. Mobile Jib crane mounted on lister
1.5T
1 1 2 3 4
4. Distilled water plant – preferably
solar system, (in ltrs per day)
1x 100
lpd
1 x 100
lpd
1 x 500
lpd
2 x 500
lpd
2 x 500
lpd
5. Portable Transformer type arc
welding set complete.
1 1 2 2 3
6. Hydraulic operated scissor – type
platform truck of 1T capacity.
1 1 2 2 3
7. Vacuum pump with gauges etc. 1 1 2 4 6
8. Portable high pressure water jet
washing machine with electric motor
driven pump.
2 2 4 4 6
9. Gas cutting set 1 1 2 2 4
10. Battery charger sets suitable for
440V, 3 phase, 50Hz AC input &
110V, 200A DC current complete
with accessories for charging
batteries
2 2 4 4 6
11. Pre cooling sockets with universal
type connector.
At each coach length.
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Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
S.N. ITEM COACH HOLDING
0-50 51-100 101-250 251-500 501-1000
12. Regenerative type Constant current
constant voltage battery charger for
2 mono blocks
1 1 2 2 2
13. Portable battery charger up to 15
amps. Capacity
1 2 2 4 4
14. Battery analyzer 1 1 1 1 2
15. Motor driven portable air
compressor set with reservoir of
suitable capacity
1 1 2 2 4
16. Lathe machine, 1000mm between
center complete including spares
and accessories with attachment for
precision grinding and tapering.
-- -- 1 1 1
17. Dynamic balancing machine for
balancing of fans, shafts &
alternator pulley.
1 1 1 1 1
18. Medium sized electric motor driven
pillar-drilling machine complete.
1 1 2 2 2
19. Bench vice 2 2 4 4 6
20. Heavy-duty motor driven
pedestal grinder complete
1 1 2 2 2
21. Hydraulic puller 50T -- -- 1 1 1
22. Hydraulic puller 10T 1 1 2 2 4
23. Hydraulic press machine 2T -- 1 1 1 2
24. Portable electric motor driven drill
machine
2 4 6 8 10
25. Portable electric motor driven
grinder
1 2 3 4 5
26. Escorting staff tool boxes with tool
kit as per RDSO
For each escorting technician
27. Digital Megger upto 2.5 kV 1 2 2 4 4
28. Vacuum cleaner industrial type 1 2 2 4 4
29. Refrigerant recovery plant 1 1 2 2 4
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Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
S.N. ITEM COACH HOLDING
0-50 51-100 101-250 251-500 501-1000
30. Electronic weighing machine up to
15kg
1 1 2 2 3
31. Electronic weighing machine up to
500kg
1 1 2 2 3
32. Testing equipment (variable voltage
supply AC & DC, transistor tester,
meter testing kit etc.)
2 2 4 4 6
33. Electric motor driven de-watering
pump set for pits.
1 1 2 2 2
34. Portable electric motor driven
blower
2 2 4 4 6
35. 46.7 Ltrs spare oxygen (7 m3 )
cylinders
2 4 4 8 15
36. 41 Ltrs spare Acetylene (5.5 m3 )
gas cylinders
2 4 8 8 15
37. 46.7 Ltrs spare Nitrogen (7 m3 ) gas
cylinders
2 4 8 8 15
38. Spare refrigerant cylinders 4 6 8 10 15
39. Oven for drying electrical motor etc.
size as per requirement.
1 1 1 1 1
40. DG set, 415V of adequate capacity as
standby power supply.
1 1 1 1 1
41. Step up transformer 415V/ 750 V of
adequate capacity as standby power
supply.
1 1 1 1 1
42. 415V/ 750 V power supply points
along the pit
At each coach length
43. Injector testing & calibration
machine.
1 1 2 2 2
44. Injector leakage testing machine 1 2 2 4 6
45. Hot air Gun 1 1 2 2 2
Note: Air quality measurement facility and DG set exhaust air pollution check facility
have been withdrawn due to high value items as discussed in the meeting held at
Jagadhari workshop on 19.04.2012.
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Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
II. TOOLS
S.N. ITEM COACH HOLDING
0-50 51-100 101-250 251-500 501-1000
1. Set of Miscellaneous tools:
Torque wrenches
Special spanner
Soldering iron
De-soldering pump
Manual cable crimping tool Hydraulic
crimping tool
Cable stripper
Cable cutter
Pliers
Screw drivers
Line tester
Cell tester
Test lamp
Hammers
Mallets
Riveting tool
Punching tool
5
sets
5
sets
10
sets
10
sets
15
sets
2. Set of Measuring tools:
Dial indicators
Filler gauge sets
Vernier calipers
Vernier micrometers
Torque wrench
Depth gauges
Screws gauge
Go/No Go gauges
Hydrometer etc.
2
sets
2
sets
5
sets
5
sets
10
sets
3. Set of Special tools for RMPU:
Refrigerant leak detector
Tube cutters
Pinch off tool
Flaring tool
Charging line
Hand shut off valves
Combination gauge
Air flow meter
2
sets
2
sets
5
sets
5
sets
10
sets
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Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
Contact less thermometer
LP gauge
HP gauge
Tube bender
Lapping machine
4. Set of Electrical testing tools:
Digital multi meters
Industrial grade AC & DC voltmeters
Industrial grade AC & DC ammeter
Digital tongue tester
Insulation tester
Contact less thermometer
Digital thermometer
Infrared thermometer
Non contact type digital tachometer
Anemometer
Hygrometer
Lux meter
2
sets
2
sets
5
sets
5
sets
10
sets
5. Digital dB meter (Noise level
indicator)
2 2 2 4 6
6. Shock pulse meter 1 2 3 4 6
7. Techo meter 1 1 1 2 2
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Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
17.0 SOME MODERN EQUIPMENTS
a. Automated Wheel Diagnostic System (WDS)
b. Automatic in motion Train Washing System
c. Water recycling treatment plant
d. Mobile Lifting Platform
e. Bogie/Car body lifting system
f. Under floor bogie repair hoist
g. Turn table
h. Waste removal system for Bio-Toilet
18.0 Automated Wheel Diagnostic System
A- DDeessccrriippttiioonn:: Wheel Diagnostic System is a fully automatic and in
motion inspection and testing unit for the diagnosis of wheels of
vehicles in operation.
B- Wheel diagnostic system aims at the following types of diagnostic
work :-
a. Vehicle/wheel set identification
b. Measurement of roundness of wheel and detection of value of
out of roundness
c. Detection and measurement of flat spots
d. Measurement of tread diameter and detection of overshooting
of operational tolerances
e. Measurement of wheel profile and detection of overshooting of
operational tolerances
f. Detection of cracks
Probable source: 1. Hegenscheidt –MFD GmbH & Co Kg
P.O. Box 1652-D-41806 Erkelenz
Website : www.hegenscheidt-mfd.de
Fax- 0049(0) 2431 86 470
Indian agent : M/s VGI Power Systems(P) Ltd.
16-A, Palam Marg, Vasant Vihar
New Delhi-110057
Contact person (India): 1. Mr. Jaspreet Singh
Mobile no. 09810421620
2. SAB Wabco
Cost : Rs.5.0 Crores
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Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
18.1 Technology:
A. Wheel diameter/wheel profile measurement (laser based)
The moment wheel passes over the rail, a beam of light is passed on to
the wheel from under it. The emerging rays are received by a receiver
and fed to a computer which evaluates the inputs. By using Opto-
electrical equipments and high resolution digital cameras and
computers which are capable of accurately processing the digital
data, the wheel profile measurement can be performed.
BB.. DDeetteeccttiioonn ooff ffllaatt aarreeaass && oouutt ooff rroouunndd
Along a stretch of track equal to the circumference of the wheel, distance
between the track and the wheel crown is continuously measured
electronically and evaluated by a computer. The flat areas are detected by
the variations of height between track and the wheel crown. The difference
between largest and smallest diameter will give the measurement of
out of round.
CC.. CCrraacckk ddeetteeccttiioonn
Two ultrasonic scanning heads each are integrated in the left and right rail
of the track, when a wheel passes through the scanning heads, this transmits
ultrasonic impulse for the detection of the cracks on the tread surfaces.
By providing wheel diagnostic system, it will pre-warn the condition of
wheels. This will help in -
Average planning of wheel profiling and wheel change.
Improved safety and reliability
Improved wheel life.
Reduction in examination time and manpower.
Based on above benefits the provision of wheel diagnostic system is justified.
(Photograph on next page)
CAMTECH/2016/M/LHB INFRA/1.0 32
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
18.2 Photograph of Wheel Diagnostic System
18.3 Layout of Wheel Condition Monitoring System
Inrail installed wheelset diagnostic system
Wheel Condition Monitoring System •
Identi - fication
roundness and
flat spot
basic module
diameter cracks profile and
back to back
database
Remote access
Data exchange
Inrail I nstalled wheelset diagnostic system
Wheel Condition Monitoring System •
Identi - fication
roundness and
flat spot
basic module
diameter cracks profile and
back to back
database
Remote access
Data exchange
In Rail Installed Wheel Set Diagnostic System
CAMTECH/2016/M/LHB INFRA/1.0 33
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
19.0 Mobile Lifting Platform
(Aerial work lift platform)
Description : Battery powered aerial work lift platform with hydraulically
operated scissor lifts.
Source of supply : 1. JLG Industries Inc
1- JLG Drive,McConnellsburg,PA, USA
Contact person (India): Mr.Sunil Jain Reg.Mgr
Mobile no. 09810119569.
2. NeueroTechnologies GmbH, Germany
Cost : Rs.15 Lakhs
CAMTECH/2016/M/LHB INFRA/1.0 34
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
20.0 Coach lifting system
Description : Coach lifting system with under floor lifting plant and car
body stand.
Source of supply : 1. Neuero Technologies GmbH
Germany
Indian agent : M/s LAN Railtech. Pvt. Ltd.
K-1/81, C.R. Park, Ist floor
New Delhi-110019 Tel. 011-26271369, 26276449
Contact person : Mr.O.N.Jalota Jt.Managing Director
Mobile no. 09810158226
2. M/s Pfaff
D-86316, Friedberg/Derching,Germany
Cost : Rs.3.0 Crores
Lifting Jacks: 1. Jamalpur Workshop, Jamalpur
20.1 Photograph of Coach Lifting System
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Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
21.0 Wheel changing system
Description: Elevated track with split rail bridges and wheel set changer
Source of supply : 1. Neuero Technology
Germany
Indian agent : M/s LAN Railtech.Pvt.Ltd.
K-1/81, C.R.Park, Ist floor
New Delhi-110019 Tel. 011-26271369,26276449
Contact person : Mr. O. N. Jalota, Jt. Managing Director
Mobile no. 09810158226
2. Windhoff, Germany
Cost : Rs.2.6 Crores
20.1 Photograph of Wheel changing system
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Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
22.0 Automatic in-motion train washing system (ACWP) with water
Recycling plant.
Description : Automatic in-motion coach/train washing plant for exterior,
roof and under carriage cleaning with high pressure cleaning jet and with
vertical and horizontal rotating brushing unit .
Source of supply : 1. M/s Wesurail - US
2. M/s Bingham - UK
3. Kokan Railway
Cost : Rs………
22.1 Photograph of Automatic in motion train washing system
Cleaning of coaches is the problem of the entire Indian Railways. Washing
and cleaning of coaches is one of the though and critical jobs to be carried
during train examination. The train movement on the such dusty/sultry
climate of the region, to ensure desired level of cleanliness of coaches of
Railways passenger trains is a real challenge. The rakes of these trains are
examined and maintained at C&W Depot During examination of these
rakes, internal and external cleaning and washing of coaches is being
carried out. It is observed and studied that oily & sticky smoke emitted by
Diesel Locos especially in tunnels result in sticky soot and stains being
formed on the coaches thus resulting in a real problem of cleanliness of the
CAMTECH/2016/M/LHB INFRA/1.0 37
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
coaches and this has attracted public criticism also. As the staff is limited,
the desired level of cleanliness cannot be done satisfactorily by
conventional method within limited time period.
22.2 AUTOMATIC COACH WASHING PLANT
To overcome the above problem of coach cleanliness, a method of external
cleaning of coaches by high-pressure water jet pump was adopted earlier.
Seeing at number of staff involvement in carrying out coach cleaning, coach
washing plant is developed. In this plant, external cleaning of coaches of a
rake was done at PA, Madgaon & Kurla by horizontal rotating nylon
brushes while passing through.
Eight powered nylon brushes were provided in this plant for the purpose of
rubbing of soap solution and cleaning of dirt on external surface of coach .
1.Stages of
a) Pre-wash,
b) Spraying of pressurized soap solution mixed with compressed air.
c) After wash with high-pressure water jet were developed and
incorporated in this washing plant.
In addition to horizontal nylon brushes, two Coir brush fixtures were
developed and fitted in this plant. These coir brushes were static (non-
rotating type) and fixed in one position for the purpose of even application
and rubbing of soap solution on surface of coach, thereby sticky particles of
soot and dirt get loosened and removed. But this coir brush could not touch
and clean the area near window-sills, upper and lower portions of coach
since upper portion of coir brush was obstructed by coach indication lamp,
indication board, destination board and lower curved portion (turn under) of
coach due to less stiffness of coir brush. Hence these portions were used
to be cleaned manually by available staff.
This plant is developed with keeping in view the following points in mind.
a) Less and economical maintenance of the modified washing plant.
b) Less manpower requirement for operation and maintenance this plant.
c) 95% exterior cleaning of a entire rake of 24 coaches is to be achieved
within 35-40 minutes.
d) Reduction in water and soap solution consumption compared to the
conventional Manual coach cleaning.
e) Reduction in power consumption by using automation.
f) Cleaning and disinfection of underneath portion of toilet by High
pressure jets.
g) Bogie side cleaning by high pressure jets.
CAMTECH/2016/M/LHB INFRA/1.0 38
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
h) Roof cleaning of Coach by horizontal nylon brush.
23.0 LAYOUT AND CONSTRUCTION OF AUTOMATIC COACH
WASHING PLANT
The modified coach washing plant is situated at the entry point of rake
examination pit at coaching depot. There are four fabricated structures in
this washing plant.
1) First structure is having plan
area of 17sq.mtr. (5mX 3.4m)
and provided for PREWASH
stage. This structure is erected
at a distance of 30 meter from
second structure, to get
complete soaking of coach
with water.
2) Second structure is having
plan area of 8.16 sq.mtr.(2.4m
X 3.4m), is made from 300 x
150 mm ISBM & 300 x 90
mm „C‟ channel This
structure is provided for the
stages of SPRAYING OF
SOAP SOLUTION and
Rubbing Of Soap Solution by
vertical nylon brushes.
3) Third structure of underneath
pipelines along with air and
water reservoirs having plan
area of (4.5mX3.4m)
15.3sq.mtr. and it is provided
at distance of 16mtr. from
second structure. This
structure is provided for stages of UNDERNEATH TOILET PORTION and BOGIE CLEANING.
CAMTECH/2016/M/LHB INFRA/1.0 39
Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
4) Fourth structure is having plain area of
48 sq.m.(14m X 3.4m) and provided
for the stages of a) Moistening of soap
solution b) Roof cleaning by a
horizontal nylon brush c)Side cleaning
by four vertical cotton brushes. d)
After wash with high pressure jets.
e)Mopping by two vertical cotton
brushes. and Fourth structure is
erected at distance of 23 mtr. from
second structure, to get sufficient time
for reaction and complete soaking
with soap solution. near washing
plant.
This structure is located at start of pit line
is aligned and extended to old existing
structure of coach washing plant. It is
also made from same material used for
second structure. Central apron already
exists between the structure & track. It is
provided with proper drainage and
concrete apron in between structure and
track and nearby area at all above
locations so that waste water and soap
solution will drain out immediately to
adjacent main drainage and avoid
adverse effect on sleepers and track. Due
to proper apron and drainage,
accumulated dirt and waste are easily
cleaned and maintained with hygienic
condition.
OLD STRUCTURE OF PLANT
RENOVATED STRUCTURE
OF COACH WASHING
PLANT
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Draft Report on Infrastructural facilities for Maintenance of LHB Coaches in Open line
Water is supplied from overhead tank of 40000 ltrs. capacity to underground tank
of 10000 liters capacity (shown in figure). Water from under ground tank is
supplied to coach washing plant for Pre wash and After wash stages, by 3 HP
pump along with stand by, are located inside pump house. Soap solution is made
in overhead plastic tank of 1000 ltrs. and this soap solution is supplied to coach
washing plant for Spraying of solution stage, by one HP pump. Water pipe
connections for Pre wash , After wash , Toilet and Bogie cleaning stages are made
from 1" and 2" pipes and soap solution pipe connection is from 1" pipe. Electrical
switchgears and control panel are provided for 3 Pumps (1 for soap solution and 2
for water),motors (each 3 hp)of 1 horizontal nylon roof cleaning brush and 6
vertical cotton brushes and 2 vertical nylon brushes for soap solution rubbing, in
the pump house which is located near to washing plant. Compressed air supply,
which is already available at pit line, is tapped for soap solution spray.
Both structures and vertical brush unit have been painted with two coats of epoxy
primer and paint. Since this Iron structure and sub assemblies are more prone to
corrosion due to existing salty weather and acidic/alkaline soap solution used in
washing plant, epoxy painting is one of the better options to reduce corrosion and
the cost.
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24.0 PROCESS OF COACH CLEANING AND WASHING IN DIFFERENT
STAGES
24.1. PRE-WASH: A rake is moving at speed of 5 KMPH during cleaning
and washing of coaches through this plant. In this stage a diffuser type
sensor is provided for sensing coaches of a rake. As soon as this sensor
senses first coach of a rake, water starts spraying on external surface of
coach through number of holes provided on water pipelines erected around
in a row.
24.2. SPRAYING OF SOAP SOLUTION: In this stage, diluted soap
solution is sprayed on coach surfaces including two sides and roof through
seven sprinklers. Provision is made for mixing of compressed air with
pressurized soap solution inside the sprinklers to get more bubbles formed
when it strikes with coach surface.
Two sides and roof of
coaches are completely
wetted by low velocity
sprinklers at this stage,
some loose dust & dirt is
washed away from coach
surface and
simultaneously, coach
surface is made uniformly
wet, which help in even
application of soap
solution on coach body.
Due to release of surface tension in
bubbles, dirt particles are loosened
and washed away easily. Flow and
quantity of soap solution can be
controlled and adjusted by operating
spindle nut on sprinkler and both
valves provided on soap solution
line and pneumatic line.
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24.4. SOAKING OF SOAP SOLUTION: In this stage, soap solution is
allowed to soak completely for approx.1 minute in normal washing process.
This stage is automatically achieved while rake is moving at 5 Km/h.
through coach washing plant, since stage 3 and stage 5 is kept apart at 30
meter distance. During this stage, soap solution, is chemically reacted with
dirt.
This pressurized spray clean underneath portion of toilet and near by area
which is normally spoiled with wet soil. This process is also helping in
prevention of breeding of cockroaches which generally take place in this
area. Further, it also helps in maintaining hygienic conditions for working
staff, who specially work or attend safety fittings in this portion of a coach.
In this stage, sides of bogie are also cleaned by high pressure water jets
simultaneously.
24.3.RUBBING OF SOAP SOLUTION: This stage is especially incorporated to get
more effective cleaning. In this stage, soap
solution is rubbed and made even
application on both sides of coach by two
vertical nylon brushes one at each side of
coach .This stage comes into action as
soon as sensor at second stage is activated.
23.5.CLEANING OF UNDERNEATH
PORTION OF TOILET: In this stage,
two sensors are provided for
ascertaining the location of underneath
toilet portion between two adjacent
coaches by sensing of last wheel of
first coach and first wheel of second
coach. As soon as these sensors are
activated in above situation,
pressurized water mixed with
disinfectant and phenol, sprayed from
bottom through four nozzles which are
provided between two rails.
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24.6. MOISTENING OF SOAP SOLUTION: In this stage, moistening of
partially dried soap solution is carried out by sprinkling of very low-
pressure water through number of nozzles provided on a water pipe line.
Hence soap solution applied on roof and sides of coach become wet before
rubbing by horizontal and vertical brushes.
AAfftteerr tthhiiss ssttaaggee,, CCooaacchh iiss mmoovviinngg
ffuurrtthheerr tthhrroouugghh 44 sseettss ooff vveerrttiiccaall
ccoottttoonn bbrruusshh uunniittss ((22 NNooss oonn eeaacchh
ssiiddee)).. TThheessee bbrruusshheess aarree mmoovviinngg aatt
tthhee ssppeeeedd ooff 115500 rrppmm.. DDuuee ttoo
cceennttrriiffuuggaall ffoorrccee,, eenndd ooff eeaacchh tthhrreeaadd ooff
ccoottttoonn bbrruusshheess ssttaarrtt rruubbbbiinngg ssooaapp
ssoolluuttiioonn oonn ccooaacchh ssuurrffaaccee wwiitthh ssmmooootthh
iimmppaacctt eeffffeecctt tthheerreebbyy wwhhaatteevveerr
rreemmaaiinniinngg ssoooott aanndd ddiirrtt aavvaaiillaabbllee oonn
ssuurrffaacceess aarree ttaakkeenn aawwaayy ccoommpplleetteellyy..
CCoottttoonn tthhrreeaadd hhaass ggoooodd ccaappiillllaarryy
pprrooppeerrttyy tthhuuss iitt hhoolldd ssooaapp ssoolluuttiioonn
ccoonnttiinnuuoouussllyy ffoorr lloonnggeerr ttiimmee.. TThheessee
ccoottttoonn ttrreeaaddss hhaavvee ggoooodd fflleexxiibbiilliittyy aanndd
ggeett rreeqquuiirreedd lleennggtthh aauuttoommaattiiccaallllyy
aaccccoorrddiinngg ttoo sshhaappee ooff ssuurrffaaccee ooff ccooaacchh
ssoo tthhaatt oonnllyy ttiipp ooff tthhrreeaaddss ggeett ttoouucchheedd
wwiitthh ccooaacchh ssuurrffaaccee.. CClleeaanniinngg bbyy tthhiiss
mmeetthhoodd hhaass sshhoowwnn ssiiggnniiffiiccaanntt eeffffeecctt..
TThheessee ccoottttoonn tthhrreeaaddss aarree ssppeecciiaallllyy
ggiivveenn ssttiiffffnneessss bbyy ffaasstteenniinngg wwiitthh nnyylloonn
bbrriissttlleess ttoo pprreevveenntt mmiinngglliinngg ooff ccoottttoonn
tthhrreeaaddss..
TThheerreeffoorree,, ttiippss ooff bbrruusshheess aarree
rreeaacchhiinngg ,,ttoouucchhiinngg aanndd ddooiinngg cclleeaanniinngg
aatt iinnttrriiccaattee ppllaacceess oonn ccooaacchh bbooddyy lliikkee
wwiinnddooww,, wwiinnddooww ssiillll,, wwiinnddooww sshhuutttteerr,,
ddoooorrss ,, ssppaaccee nneeaarr ddoooorr iinncclluuddiinngg ddoooorr
hhaannddllee,, ssppaaccee nneeaarr ttoo ddeessttiinnaattiioonn
bbooaarrdd,, ttuurrnn uunnddeerr aanndd rrooooff ppoorrttiioonn..
EEaarrlliieerr,, tthheessee aarreeaa ccoouulldd nnoott bbee
ppoossssiibbllee ttoo cclleeaann bbyy oolldd ccooaacchh
wwaasshhiinngg ppllaanntt.. TThheessee bbrruusshheess aarree aallssoo
hheellppiinngg iinn rreemmoovviinngg ooff rreesseerrvvaattiioonn
cchhaarrtt ppaasstteedd oonn aa ccooaacchh..
24.7.COACH CLEANING BY HORIZONTAL AND VERTICAL BRUSHES:
WWhheenn ccooaacchh iiss mmoovviinngg tthhrroouugghh tthhiiss ssttaaggee,, ffiirrsstt rruubbbbiinngg ooff ssooaapp ssoolluuttiioonn ttaakkeess
ppllaaccee aatt rrooooff ppoorrttiioonn bbyy hhoorriizzoonnttaall nnyylloonn bbrruusshh mmoouunntteedd oonn ttoopp ooff tthhee IIVVtthh
ssttrruuccttuurree..
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24.9.MOPPING OF WATER: After wash, coach body become
completely wet hence it require mopping. Two vertical brushes with
soft cotton threads are provided each on either side. These brushes
start mopping of water particles on sides of coaches as soon as coaches
pass through these brushes.
This stage is specially effective for
cleaning of AC glass windows where
small water drops are always sticking
and staining glass giving discomfort to
passengers when they are looking
outside through such windows. These
brushes are also used for buffing of
coaches to get shining by rotating it in
dried condition when rake is moved
from pit-line after examination. Since,
requirement of soap solution is less for
external cleaning of rake by this washing
plant. Cost incurred in normal external
cleaning of a rake of 21 coaches is Rs.
400 approximately. This cost includes
cost of material like soap solution and
cotton ropes (which are normally
replaced once in a month) and cost of
electrical power.
24.8. AFTER WASH: In this
stage, washing of roof and sides
of coaches are carried out after
rubbing of soap solution by
vertical and horizontal brushes.
High-pressure water is sprayed on
coach surface through eight high-
pressure sprinklers to wash coach
completely. In this stage, washing
of roof takes place just before
washing of sides by spraying of
water through high velocity
sprinklers provided at top of
structure. This arrangement is
made purposely to allow dirty
water after roof washing to flow
down on both sides of coaches
before washing of sides of
coaches.
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25.0 Water Recycling treatment plant :
The water recycling in Railway coaching depots may help in conservation of water.
Details of components of water recycling plant for 100 m3 /
/hr. are given below:-
A. Waste water collection sump:
Qty.- One No.
Size – underground 2.5M x 2.5 M x 4M
B. Booster pumps:
Qty.- Three units
Type- Horizontal Mono block type electrically operated with 3-phase 440 V AC.
C. Online Coagulation dosing plant:
Qty.- One unit
Type- Online operation for dosing of liquefied coagulant in water before primary
settling tank.
D. Online chlorination plant:
Qty.- Two units
Type- Online operation for dosing of liquid chlorine solution, i.e. Sodium
Hypochlorite solution at pre and post filtration stages.
E. Water settling tank:
Qty.- Two chambers
Type- Over ground sump type. Both the chambers are inter-connected on top for
trickling of water for easy settling of suspended impurities and subsequent
removal by double filtration.
F. Pressure filtration plant:
Qty.- Two units
Type- M.S. vertical down-flow model with dish ended M.S. shell and at bottom
four legs.
25.1 Process of Water Recycling:
1. Waste water is collected in a sump received from washing line drainage.
2. Water is feed to settling tank by submersible pump.
3. Before feeding to settling tank water is coagulated with the help of pre-
chlorination plant.
4. Time required for settling of impurities in settling tank is 3 hrs.
5. Supply of water for re-using in washing of trains is supplied through two
mono-block pumps via two vertical filtration plants connected in series.(Pre-
filtration and Post-filtration plant).
6. Chlorine is added in suitable amount after filtration for post-chlorination.
7. After post-chlorination, water is supplied for washing of trains in
washing line.
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Fig.25(a) Systematic Diagram of Installation of Water Recycling Plant.
Fig. 25 (b) Execution plan for water recycling plant.
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26.0 INTERNAL COACH CLEANING MACHINE
This machine is departmentally designed and developed for cleaning of
coaches internally. It is operated on 220V AC as well as 110VDC supply
thereby any coach lying any where in the yard can be cleaned by this
machine as 110V DC supply available in a coach. Construction of this
machine is sturdy and light in weight about 6 Kg hence it is easy to handle.
Due to light weight and 1.2 meter length of machine, staff can do effective
cleaning work in standing position without fatigue. At present, this machine
is specially used for toilet cleaning and intensive cleaning of floor, berth,
side wall by using various type of brushes.
FLOOR CLEANING BERTH CLEANING
WINDOW GLASS CLEANING TOILET CLEANING
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27.0 TRANSPORTATION CODES FOR LHB COACHES
[ Ref: APPENDIX ‘D’ of Maintenance manual for LHB ]
Sr.No TYPE OF LHB COACH CODE
1 AC FIRST CLASS SLEEPER- (EOG) LWFAC
2 AC FIRST CLASS SLEEPER- (SG) LWGFAC
3 AC SECOND CLASS SLEEPER- (EOG) LWACCW
4 AC SECOND CLASS SLEEPER- (SG) LWGACCW
5 AC THREE TIER CLASS SLEEPER- (EOG) LWACCN
6 AC THREE TIER CLASS SLEEPER- LACCN (SG) LWGACCN
7 AC DOUBLE DECKER AC CHAIR CAR (EOG) ACCC DOUBLE DECKER
8 AC HOT BUFFET CAR LWCBAC
9 LHB GS EOG coach fitted with the new inner spring design of
secondary suspension (LW05127) with a combination of existing
LG05101 outer spring (Shalimar coach secondary outer spring) and
Rubber spring with 36 mm shim.
LS4
10 NON AC SECOND CLASS THREE TIER–(SG) LWGSCN
11 NON AC- LUGGAGE CUM GUARD VAN(SG) LGSLR
12 AC CHAIR CAR EXECUTIVE CLASS LWFCZAC
13 AC CHAIR CAR LWSCZ AC
14 GENERATOR CUM LUGGAGE& BRAKE VAN LWLRRM
15 EOG NON AC HOT BUFFER LHB COACHES LWCB
16 EOG AC FIRST CLASS CUM AC TWO TIRE LHB COACH LWFCACCW
17 II class non-AC EOG LHB variant in BG coach fitted with
modified suspension on FIAT bogie with suspension to Drawing
No. LG 90018 with 32 mm shims without 2 under slung water tanks
of 685 Lt capacity, luggage rack shifted upward by 440 mm.
LS 2`
18 II class non-AC EOG LHB variant in BG coach fitted with
modified suspension on FIAT bogie with suspension to Drawing
No. LG 90019 with 32 mm shims without 2 under slung water tanks
of 685 Lt capacity, luggage rack shifted upward by 440 mm.
LS 3
19. EOG non AC chair car LHB variant coaches fitted with FIAT bogie
with 16.25 t axle load
LWSCZ
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Suggestions given by Zonal Railways for Coaching Depots during
seminar on 21.07.2014
Pit line: Dy CME/NWR, Sr DME/BSP & Dy CME/GKP stated that prefab pit line in line with
DMRC will be suitable but both side catwalks are required alongwith long span supports below
catwalk.
Catwalk: Catwalk is necessary for changing of destination boards, cleaning of exterior,
attention to doors, cleaning of roof and attention to ventilators. But these catwalks make clumsy
situation due to supporting pillars, hence it is suggested that pre-fab longer span catwalks may
be developed for better and safe maintenance.
Pre-Cast tiles: For free movement of staff from one pit line to other pit line at entry point, floor
of pre-cast tiles for atleast half of the coach length should be done for safe travelling.
Lighting arrangement: Light fittings of sufficient lux should be installed on Catwalk pillars for
under gear and trolley inspections. Single phase Welding sockets, and spare plug for hand lamps
should also be provided on this switch board.
Surface wheel lathe machine: Surface wheel lathe machine is required for coaching depots
having holding more than 250 coaches.
Maintenance bay shed: Lay out and estimation for covered shed should be done in line with
ROH depot ADI and TKD. The details may be collected from them.
Hydraulic Jacks: Hydraulics Howrah JET. And Ferro mysore are the sources for lifting
platforms.
Cleaning Machines: Sources for cleaning machines are , Karchar, Roots India, Johnson Divery
etc. Specifications may be collected from them.
Suggestions given by Zonal Railways for Coaching Depots during
seminar on 20.07.2015
Catwalk: Catwalk is necessary
Covered shed for Pit line: Covered shed should not be provided for maintenance pit line.
Maintenance Pit line: Length of pit line should be increased to 675 meters for 28 LHB coaches.
Linen Room: Size of linen room should be increased to 10 X 10 M
Conference hall: Size should be increased to 10 X 10 M or 5 X 15 M
Air Compressor with air dryer: Air dryer should also be provided with compressor.
Sewing Machines: Nos. to be increased to 2
Pipe bending machine: 01 Pipe bending machine should be included in the list for SS air brake
pipes of LHB coaches.
Recommended