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Quality Audit report

Of

Coaching Depot

New Delhi, N Rly

Report no. 29/2012

APRIL 2012

(Audit is done by QA Mech Dte of RDSO )

Page 1 of 33 Coaching depot – NDLS, N Rly. April 2012

Quality audit report of New Delhi Coaching Depot, N Railway

1.0 Introduction - In terms of instructions issued vide Railway Board letter no.

2012/M(W)814/5 dated 20.03.12, QA/Mechanical/RDSO/Delhi has conducted the

quality audit of Coaching Depot, Delhi of Delhi division of Northern Railway.

1.1 Audit team – Shri Satish Singh, Director/I&L/RDSO/New Delhi, Shri S.L Sharma,

AIE-II/I&L/RDSO/New Delhi and Shri.S.D.Pandit, JE-I/I&L/RDSO/New Delhi.

1.2 Dates of audit – 04/04/12, 05/04/12, 14/04/12 and 15/04/12.

1.3 Escorting officers – Shri Jitendra Kumar, Sr.CDO/NR/NDLS Coaching Depot,

Shri Arjun Singh, SSE/T/NDLS, Shri Sunil Yadav, SSE/Incharge/Shatabdi

Complex, Shri P.S. Beniwal, SSE/Incharge/DLT, Shri Kharag Singh,

SSE/SL/DLT, Shri Baboo Ram, SSE/DLT, Shri V.K.Thukral,

SSE/Incharge/Rajdhani Complex, Shri Vinod Kataria, SSE/ Incharge/Linen Shri

Shashi Bhushan, JE/Linen.

1.4 Scope of audit – Primary Maintenance of coaching rake, Roller bearing section,

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

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

its management, painting, etc.

2.0 Brief about depot - New Delhi coaching depot located adjacent to the main

station is a grouping of five locations, which are as follows:

2.1 Shatabdi Complex: At Ghaziabad end, there are three washing lines namely WL-

3 with pit , WL-4 without pit and WL-5 with pit.

2.2 At New Delhi left side - Panipat end, there are two washing lines, namely WL-7

with pit and WL-8 with pit, on which maintenance attention to secondary Rajdhani

Trains and other Mail express trains with loads less than 24 coaches, is given.

2.3 DLT Complex: At New Delhi Right side - Panipat end, there are four washing lines,

namely WL-9 with pit, WL-10, WL-11 and WL-12 with pits, on which maintenance

attention to all primary Rajdhani Trains and other Mail express trains with loads of

24 coaches is given. Also, a Sick line exists wherein attention to Sick coaches,

for reasons other than wheel defects, is given.

2.4 At Panipat end, there is one area contiguous to DLT side; having five washing

lines namely WL-1 to WL-5 with pits, on which maintenance attention to LHB

Type Primary Shatabdi trains, except 12005 and all secondary Duronto,

Secondary Rajdhani (BCT & ADI) Trains and other Mail express trains is given.


2.5 Beside above, there is one IOH shed/ Sick line at Ajmeri Gate side wherein

attention to most of the Sick marked coaches of NDLS depot is given. There is

one Pit wheel lathe for re-profiling of wheels apart from other M&P.

3.0 Strengths

3.1 Rajdhani Complex, is maintaining passenger feedback in a very novel form, in

addition to the prescribed norms. For every Rajdhani train, a visitors’ book is

maintained and passengers’ feedback is obtained therein.

3.2 The Depot has developed two CDTS labs in house. This is helping the depot to a

great extent.

3.3 System of testing BP/FP hoses on 100% basis using pressure at 10 kg/cm2

before fitment in coaches is being followed.

4.0 Weaknesses

4.1 Rolling-in lights are provided at NZM end and DLI end for PF nos. 3, 4 13, 14, 15

and 16, at NZM end alone for PF nos. 1, 2, 9 and 12. It needs to be provided at

other locations. Only one rolling –in hut is provided at PF 2-3.

4.2 The condition of illumination is not at all commensurate with the work

requirement. Pillar lights and pit lights are unavailable. Bhopal Shatabdi is

maintained at Washing Line no. 5 where there is no illumination available.

Majority of electrical fittings in pit wheel lathe and sickline are out of order. This is

affecting quality of maintenance of under gear and bogies especially during night

time. Yard illumination is highly in-adequate and needs to be improved.

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

Drains in Washing Line No. WL-3, 5 at Shatabdi Complex, WL-7, 8 and DLT

Washing Line No. 5 is not proper and problem of water logging is being faced

which is major hurdle in carrying out maintenance of under gear smoothly.

4.4 It was observed that gauges provided on Rake test rigs were not calibrated.

4.5 Records produced indicate only the fact of having completed ‘A’ or ‘B’ schedule

etc. Details regarding checking of items as prescribed during the schedule could

not be made available, other than at Rajdhani Complex.

4.6 System of inspection of washed linen and accountal of return of dirty linen

received after washing was not found to be foolproof.

4.7 As far as pest/ rodent control is concerned, no record pertaining to consumption

of quantities during treatment or issue and opening of sealed containers of

chemicals could be produced. Only number of cockroaches and rats found as a

consequence of treatment is being recorded.


4.8 System of accountal, issue and consumption of cleaning chemicals could not be

produced.

4.9 Shortage of critical items with respect to requirement has been brought out by

Sr.CDO/NDLS. This shortage will reflect on maintenance of rakes.

4.10 Availability of staff for coaching maintenance as per Yard stick: Shortage of staff

and supervisor is there in the depot.

4.11 As per records, Out of 617 Technicians, 487 Technicians are overdue for training.

4.12 At Shatabdi Complex, record keeping needs to be improved. Schedule register and coach history book for conventional Shatabdi rakes need to be improved. Further, since only few entries get co-related. Details of activities being attended for A & B schedules in coaches are not being recorded. Many monitoring formats need to be revised.

4.13 At DLT and Rajdhani complex, it was observed that D3 and D4 activities are being carried out at the washing line, only to the extent possible. Sr. CDO informed that due to non availability of spare coaches, in view of large no. of coaches on POH account, it is not possible to bring coaches to sickline for D4 attention.

4.14 Travel authority for OBHS manpower on various trains have corrections/ alterations which are not bearing signatures/ attestations of authorized SSEs, e.g. 12002/01 of 19.02.12, 12011/12 of 19.02.12. This was highlighted to SrCDO.

4.15 Critical spare position for LHB coaches like Speed screws, wheel sets, all type

dampers, sealed window glass unit, Earthing unit is a cause for concern.


Quality Assurance Directorate (Mechanical) RDSO Lucknow

Check sheet for Quality audit of coaching depot

Primary maintenance attention and sick line attention

(Based on CAMTECH Maintenance Manual for BG coaches

and Railway Board / RDSO’s guidelines)

AT New Delhi COACHING DEPOT

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 –616 nos. Overdue POH – 01 No. LWLRRM, 02 Nos. 2CCEHS, 02 Nos. WSCZAC, 01 No. WGSCN

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 (For ICF Type Coaches only)

Coach holding –140 Nos. Overdue Schedule A - NIL

4. Schedule B -Quarterly (3 month ± 7 days) in rake (For ICF Type Coaches only)

Coach holding – 140 nos. Overdue Schedule B - NIL

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

Coach Category

Periodicity

New coach at interval of 12 months in Depot

Rajdhani Satabdi (Conv)

at interval of 9 months in workshop

Mail / Express at interval of 9 months in depot

Passenger at interval of 9 months in depot

Other OCVs at interval of 12 months in depot

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

Coach holding – 616 Nos. Overdue IOH – 02 Nos. LWFCZAC, 16 Nos. LWSCZAC, 03 Nos. LWLRRM, 01 No. WSCZAC, 02 No. SLR, 02 No. WGCB 01 No. WGSCN

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 This is being followed.

7. Examination of originating trains:

107 a of Chg. Manual

This is being followed.


SN Item Clause Observation 7.1 All trains must be examined by the

mechanical train examining staff before despatch to ensure all coaches are in fit condition without rejectable defects.

107 a (i) of Chg. Manual


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

107 b of Chg. Manual

This is being followed. Rolling-in lights are provided at NZM end and DLI end for PF nos. 3, 4 13, 14, 15 and 16, at NZM end alone for PF nos. 1, 2, 9 and 12. It needs to be provided at other locations. Only one rolling –in hut is provided at PF 2-3.

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

107 (b)(i)(a) of Chg.Manual Site is conducive for conducting Rolling-in-examination.

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

107 (b)(i)(d) of Chg.Manual Adequate space is available. The condition of illumination is not at all commensurate with the work requirement. Pillar lights and pit lights are unavailable. Bhopal Shatabdi is maintained at Washing Line no. 5 where there is no illumination available. Majority of electrical fittings in pit wheel lathe and sickline are out of order.

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

107(b)(iv) of Chg.Manual This is being followed. However, defects/ discrepancies noted are being informed orally to officials concerned. System of record keeping was inevident..

8.4 Temperature of the axle boxes should be measured preferably with the help of the electronic temperature measuring device.

107(b)(vi) of Chg.Manual This is being followed. Records are being maintained in the Train Duty section/Washing Line section for their nominated trains. 37 laser type recorders are available.

9. Revised maintenance pattern for coaching trains circulated vide Railway Board’s letter No.95/M(C)/141/1 dt.31.01.07

Railway Board’s letter No.95/M(C)/141/1 dt.31.01.07

9.1 While permitting introduction of round trip primary pattern of maintenance on coaching trains, approved mandatory condition at primary end and other end as detailed in Railway Board’s letter No.95/M(C)/141/1 dt.31.01.07 is followed.

Railway Board’s letter No.95/M(C)/141/1 dt.31.01.07

Yes.

9.1.1 Primary End On 04/04/12, rake of 12015, Ajmer Shatabdi and on 15/04/12, rakes of 12428, Rewa Express and


SN Item Clause Observation

12005, Kalka Shatabdi.

i) The brake gearing should be properly

adjusted including the slack adjuster ‘A’

dimension & the brake cylinder stroke to

ensure 100% brake power

-do- Slack Adjuster A Dimensions found adjusted by staff and recorded.

ii) Brake blocks should be changed in bogie sets only

-do- This is being followed. Previous records also corroborate this fact.

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

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

iv) Intensive cleaning of coach toilets and lavatory.

-do- This is being followed.In the last six months, 2050 AC coaches ( including LHB) and 89 pantry cars have been cleaned intensively. Record found maintained in Shatabdi Complex for Train No. 12015 AII Shatabdi, 12037 LDH STB and 12005 KLK Shatabdi. Cleaning of 12428, Rewa express needs to be improved.

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

-do- This is being followed. 12428 and 12005 have a pit time slot from 1030-1630 hrs. on W/L no. 3 and 1700-2300 hrs. on W/L no. 7 respectively.

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

-do- Washing lines nos. St-8,9, 10,11 are non-pit type. Welding facility is available only at WL nos. 3,4 and 5. These three lines have lot of tied rods hydrant line s corroded. Catwalks broken, OH poles fixed in pathways in DLT complex, restricting the movement of fork lifter/ Lister truck/ Wheel barrows. High Pressure Jet cleaning plant found available in Shatabdi Complex only. For other locations, maintenance is being carried out with high pressure jet cleaning machine through outsourcing.


SN Item Clause Observation vii) Adequate gang strength with proper

supervision -do- Cleaning of all trains

outsourced and manpower as per bench marking provided except Shatabdi trains which are being maintained departmentally wherein the SSE/Incharge highlighted inadequate man power. It was informed that estimates for these trains have also been vetted and planned for outsourcing shortly.

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- Rake found stabled in yard with locked condition and positive security wherever lie over was more than 02 Hrs. Verification done on the rake of Train No. 12391 and the conditions found complied with.

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

-do- Partially available. Drains’ covers & concrete path way are not available. Obstructions in movement with pipe line on PF no. 7 & 8. Water pressure becomes low at times on all the platforms. Inspection lights along the track are also not available.

iii) A joint safety certificate covering each clause of mandatory conditions will be issued by mechanical and operating branches at divisional level prior to changing over any train to revised coaching maintenance pattern.

-do- No joint safety certificate is being issued at divisional level and the changing over to the revised pattern is being done on the basis of operating order being received in the division from HQ.

10. Rake maintenance link has provision of maintenance time (pit attention) of 6 hrs at primary end to enable intensive attention.

108 of Chg. Manual and Policy circular no. 4


11. Internal cleaning, Passenger amenity attention and watering is done at platform line or nominated stabling line provided stipulated facilities are available at such line is followed

108 of Chg.Manual Table 1.8

Stipulated RPC-4 conditions are available on only on 2 stabling lines. It was highlighted by SrCDO/NDLS that keeping in view the workload of NDLS depot; such facilities are required on 5 more stabling lines.


SN Item Clause Observation 12. Washing and cleaning of coaches 109 of Chg.Manual

12.1 Use recommended solutions for cleaning

as per RDSO specification No.

M&C/PCN/101/2001 or use cleaning

agents approved by CME of the Railway

109 of Chg.Manual This is being followed. Cleaning activity is outsourced except for Shatabdi Complex. Cleaning compounds of Johnson Diversey/ Eureka Forbes/ Pudumjee Hygiene are prescribed and being used. Isolated cases were seen in which some local brands were used in emergencies. System of accountal, issue and consumption of cleaning chemicals could not be produced. Chemicals are being stored at four locations.

12.2 It should be ensured that the rake/coach is protected with proper board/signal for safety of the staff working on washing/cleaning job to prevent movement/disturbance in the activity. Scotch blocks with locking arrangement should protect lines and keys should be kept with Engineer (C&W) till the time rake is under maintenance

109 (b)(i) of Chg.Manual Rakes are being protected properly with scotch block & locking arrangement. Verification done in Rakes of 12428, Rewa Express and 12952, Mumbai Rajdhani.

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

109 (b) of Chg.Manual This is being attended. Checked on coach nos. WGACCN 06149, LFCZAC 09906 & 09903, LWSEZAC 09159, WGSCN 07204 and GS 07411.

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

109 (c) of Chg.Manual This is being followed. Toilet cleaning needs to be improved further. Distingt marks could be observed on the wash basins and pans in majority of the coaches of 12428.

12.5 Internal cleaning of upper class AC and sleeper coaches: Check that guidelines as detailed in CAMTECH manual are being followed.

109 (d) of Chg.Manual This is being followed. Please refer item 12.3 above for coach numbers.

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

109(e) of Chg.Manual This is being followed. This needs to be improved. Please refer item 12.3 above for coach numbers.

12.7 Cleaning of buffers and screw couplings 109(f) of Chg.Manual This is being followed. Toilets appeared washed rather than cleaned. Please refer item 12.3 above for coach numbers.


SN Item Clause Observation (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 This is being followed. Please refer item 12.3 above for coach numbers.

(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 This is being followed. Please refer item 12.3 above for coach numbers.

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 09 Nos. Washing Lines out of 14 are having 24 Coach length capcity. (W/L No. 9 to 12 and DLT-1 To DLT-5).

(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 Plant for such cleaning attention was found available in Shatabdi Complex of the depot only. Mechanised external cleaning is being done.

(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 The condition verified for attention in PF at New Delhi. Water Hydrants found sufficient (72 Nos.) at PF No. 4 when checked for Train No. 12137 Punjab Mail and at PF No. 8 for Train No. 12472 water hydrants found to be 75. Water leakage was observed in a number of Water hydrants.

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

110(a)(iv) of Chg.Manual Adequate number of RTR and SCTRs are available. However, it was observed that gauges provided on these equipments were not calibrated.

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

(i) Air brake with twin pipe graduated release

system

110(b)(i) of Chg.Manual Yes.

(ii) Only enhanced capacity draw gear and screw coupling to RDSO sketch No. 79061 and 79067 are to be provided on the rake

110(b)(ii) of Chg.Manual Yes.

13.3 Maintenance practices and system related requirements

110(c) of Chg.Manual On 04/04/12, rake of 12015, Ajmer Shatabdi and on 15/04/12, rakes of 12428, Rewa Express and 12005, Kalka Shatabdi.


SN Item Clause Observation i) The integrity of the rakes to be maintained. 110(c)(i) of Chg.Manual This is being followed.

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

110(c)(ii) of Chg.Manual This is being followed.

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

110(c)(iii) of Chg.Manual This is being followed.

iv) It is mandatory to provide secondary maintenance to all trains augmented to 24 coaches (RPC 4 revised and permit Round trip attention with approval of CME)

110(c)(iv) of Chg.Manual This is being followed.

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

110(c)(v) of Chg.Manual This is being followed. Endorsement in this regard is also being done in Air Brake Diary on daily basis.

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

110(c)(vi) of Chg.Manual Not applicable to the depot.

vii) Provision of audio visual alarm system on the locomotive

110(c)(vii) of Chg.Manual Not applicable to the depot.

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

111(f)(i) of Chg.Manual This is being attended through outsourcing.

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

Coach type Nos of FE’s

Each Break Van 2 nos

Each AC coach 2 nos

Each Pantry car 4 nos

Each Generator van

2 nos

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

This is being followed. Checked in 12428, Rewa Express, 12425 JAT Rajdhani Express and found in order.

15. Similarly, other brake van equipment, which Mechanical Train Examining staff is responsible to supply, should be provided according to the instructions of each Railway. Portable control telephones, portable train lighting equipments, portable fire extinguisher, wooden wedges/skids and stretcher are to be provided.

111(g)(i) of Chg.Manual DCP Fire Extinguisher and wooden wedges are being provided by C&W, same is being ensured by maintenance C&W engineer. Other items being supplied by their respective Department. The rake of 12428 Rewa Express checked for availability of such equipments on dt. 15/04/12 and equipments were found available.

16. Watering and cleaning of rakes

Mechanical department of each railway will nominate the watering and the cleaning stations on the railway.

111(h) of Chg.Manual This is being followed.

17. Deficiency Rolling Stock (DRS) for Coaching Stock

111(i) (i) of


SN Item Clause Observation (i) Railway should devise system for

detecting deficiencies. Reports of deficiencies/ defects in Rolling Stock (DRS) reports in the proforma given in Annexure 1.2, should be prepared for each mail/express/passenger originating train in duplicate by the Engineer (C&W)/Electrical (TL) and should be signed jointly with the RPF representatives.

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

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

111(5)(b) of Chg.Manual Joint report is made in reported case of theft only.

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

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

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

(ii) The complete history book of each coach, consisting of maintenance history cards, date card, trial card, etc. will, however, be maintained by the base workshops

111(k)(iii) of Chg.Manual This item pertains to Workshop.

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

given a Primary/Secondary Maintenance examination as prescribed by the Chief Mechanical Engineer of the Railway and as per Appendix F of Chg.Manual

113(a) of Chg.Manual This is being followed.

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

113(b) of Chg.Manual This is being followed to the extent of availability of water.

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

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

113(c) of Chg.Manual This is being followed.

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


SN Item Clause Observation 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

Level of 40mm. is being maintained and record found maintained in Rajdhani and Shatabdi Complex.

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

113(e) (ii) of Chg. Manual This is being followed.

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 This is being followed.

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 This is being followed.

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

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

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

v) Window shutters should neither be tight nor loose

113(f)(v) of Chg.Manual

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

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

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

113(f)(viii) of Chg.Manual

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

113(f)(x) of Chg.Manual

x) Drain grills and drain holes in the bathroom floors and wash basin drainpipes should be cleaned and opened where found choked.

113(f)(xi) of Chg.Manual

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

113(f)(xii) of Chg.Manual

xii) A proper record should be kept by Engineer (C&W) at washing/pit lines of schedules carried out by them, especially of items required to be attended at specific periodicity. Record to be maintained in standard DDR (Damage deficiency register)

113(h) of Chg.Manual Records of DDR diary for 14/04/12 and 15/04/12 were checked. It is, however, not possible to correlate the dates of previous attentions done on a particular coach, in the absence of a monitoring software.


SN Item Clause Observation 20. Schedule ‘A’ Examination 114 of Chg.Manual Rake of 12428 checked.

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

114 (a) of Chg.Manual This is being followed.

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

114(b) of Chg.Manual This is being followed.

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

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

21. Schedule ‘B’ Examination 115 of Chg.Manual

i. Schedule `B' is required to be given every three months + 7 days at the nominated primary maintenance depot within the normal time allowed for primary maintenance on a washing line in rake.

115(a) of Chg.Manual This is being followed.

ii. The specified items of work should be attended.

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

iii. Brake system maintenance

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

Chg. Manual This is being followed.

iv. Other assembly maintenance

Besides brake system other items should be attended as given below:

115(b)(i) of Chg.Manual

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

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

c. Thorough inspection and repairs of brake gear components.

115(b)(iv) of Chg.Manual

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

115(b)(v) of Chg.Manual

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

115(b)(vi) of Chg.Manual

22. IOH attention

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

22.1 Periodicity of IOH attention:

Coach Category

Periodicity

New coach at interval of 12 months in Depot

Rajdhani Shatabdi

at interval of 9 months in workshop

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


Coach no. WGACCNW 08879 and WACCNH 07947 and GS 16334, undergoing IOH were


SN Item Clause Observation (Conv)

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

checked.

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

IOH Attention to non-LHB Stock including conventional Shatabdi, Rajdhani and Garib Rath stock excluding Power Cars is given at Sick Line.

22.3 Brake system: ‘C’ schedule maintenance

(IOH) as per para 426 of air brake chapter. 117(a)(i) of Chg.Manual This is being followed.

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

117(a)(vii) of Chg.Manual This is being followed.

22.5 Other assemblies maintenance

All items of Schedule `B' 117(a)(i) of Chg.Manual This is being followed.

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 This is being followed.

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

117(a)(iii) of Chg.Manual This is being followed.

22.8 Polishing of the polished surfaces. 117(a)(iv) of Chg.Manual This is being followed.

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 Though workshop overhauled shock absorbers are being used, it was seen that availability of spare shock absorbers was meagre.

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 Wire brush is being used for cleaning rather than compressed air and coir brush.

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

117(a)(vii) of Chg.Manual This is being followed.

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 This is being followed.


SN Item Clause Observation 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 This is being followed.

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

117(a)(x) of Chg.Manual This is being followed.

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 Interaction with Shri Jugal Kishore, SSE and Shri Durga Prasad, JE, revealed their knowledge to be satisfactory.

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 Please refer item 22.10 above.

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 This is being followed.

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 This is being followed. However, records produced indicate only the fact of having completed ‘A’ schedule. Details regarding checking of items as prescribed during the schedule could not be made available.

22.17

For maintenance of coaches of Rajdhani/ Shatabdi Express Rakes, the instructions given in RDSO Technical Pamphlet No. C-7807 should be followed.

118 (b) of Chg.Manual This is being followed.

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

118(c) of Chg.Manual IOH attention to conventional Shatabdi and Rajdhani stock is being done in workshop. However, in order to liquidate overdue running of coaches, one time permission has been accorded as a special case to carry out IOH in the depot by bringing overhauled trolleys from workshops excluding Power Cars.


SN Item Clause Observation 23 Linen management

i. Complete activity of linen management including washing, storage, supply & distribution of linen kits in trains shall be done by Mechanical (C&W) Dept as a single window agency

Board’s letter No.2009/M(C)/165/6 dt.17.12.2009.

Yes. Washing, storage and

distribution is being done

through outsourcing.

ii.(a) Stock verification of linen should be carried out on a quarterly basis

Board’s letter No.2009/M(C)/165/6 dt.4.1.2010

Evidence of physical stock verification could not be made available. It was informed that same was carried out two years back.

ii.(b) At least 5% of new linen should be checked by SSE/Mechanical for: (a) bundles being sealed and having batch nos., manufacturer’s name, year of manufacture, quantity, size indicated, (b) Linen items having marking of month / year of manufacture, Railway, etc. (c) dimensional check, colour, feel and workmanship, etc.


ii.(c) Monthly report of inspections / test checks of the linen washing contractor’s premises

by officers / supervisors, should be prepared and payment should be made after recovery of all penalties / dues

This is being followed. Records of linen check at supervisory level were seen. Super-check records at Depot officers’ level could not be seen. It was informed that system exists for rejection/ return of any soiled/ dirty linen entering the circuit after washing. System exists for forwarding necessary advices in regard to imposing deductions from the contractor’s bills in case of default. On 15/04/12, 2 packets

from two different bags

were checked at random

and bed sheets were

found in damp condition.

Shri Shashi Bhushan, JE

informed that he had

inspected and returned

few bags to the

laundryman on that day’s

inspection of washed linen.

However, related Memo

no. 72, dated 15.04.12

was seen which had no

posting in this regard.

System of inspection of

washed linen and

accountal of return of dirty

linen received after



washing was not found to

be foolproof.

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

This is being followed. As per the daily position of linen availability on 12/04/12, 51059 bed sheets, 19395 pillow covers, 26203 face towels and 4638 blankets were available at the depot.

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

This is being followed to the extent of availability. Availability of bedsheets, pillow covers, face towels and blankets (AAC of 11-12/ Actuals) as on 12/04/12) is as follows, respectively; 191240/ 137303, 95620/ 46638, 191240/ 58785 and 15870/ 17693.

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


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

This is being followed. However, blanket sanitization methodology was not found to be working. A container has been converted as a room for this purpose in which blankets were found hanging in fully folded condition, with the blower not giving the desired hot draft. Shri Shashi Bhushan, JE, did not appear to have any clue regarding efficacy and effectiveness of the system in vogue.

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

This is being followed. Records of the same are available. 09-10 : 337 complaints 10-11 : 761 complaints 11-12 : 66 complaints

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


24. Pest / Rodent Control

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

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



SN Item Clause Observation ii. All reserved (both AC and Non-AC)

covered under contract, unreserved coaches may also be covered as per requirement of Railways


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

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

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

This has been clearly specified. Chemicals like ICON powder, Roachex, Nuvan, Maxforce IC, Dart Super powder and Express-35 have been prescribed alongwith their concentration/ dilution ratios. As far as pest/ rodent control is concerned, no record pertaining to consumption of quantities during treatment or issue and opening of sealed containers of chemicals could be produced. Only number of cockroaches and rats found as a consequence of treatment is being recorded. On 15/04/12, last record shown in Shatabdi complex was up to 03/04/12.

v. Minimum frequency of rodent control treatment is adhered to : AC coaches / Pantry cars : during every Primary maintenance, Reserved Non-AC coaches : Weekly Maximum tolerance +7 days, on account of operational exigencies, disturbance of rake links, etc.

AC-Weekly PC-Weekly Non-AC: Bimonthly. (Minimum frequency is being ensured in every section of the depot)

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


vii. Fumigation/mist treatment carried out whenever coaches detached for IOH/POH. Pest/rodent control carried out before inducting the coach in service after IOH/POH

This is not being done. However, provision exists in the fresh contract under finalization in the division.

viii. In order to prevent cross infestation, contractor may make effort to treat all AC and all Non-AC coaches of a particular rake together


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

This is being followed. Coach nos. GSCN 07204, WGACCN 06149, WGS 07411, LFCZAC 09903



were checked and found in order.

x. Railways shall make effort to detach pantry cars from rakes once a month (within reasonable tolerance) to facilitate complete vacation and intensive cleaning for thorough pest / rodent control treatment

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

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

Reduction in level of infestation is being monitored.

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

Yes. 09-10 : 55 complaints 10-11 : 44 complaint 11-12 : 18 complaints

25. Passenger amenities provided in various

types of coaches as specified

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

Checked rake of 12428 and coach no. GSCN 07204. Minor deficiencies could be noticed.

26. Infrastructure facilities – Standard

integrated modular pit line have unified maintenance.

Appendix ‘E’ of Coaching manual CAMTECH report No.CAMTECH/M/99/Infra-washing line/1.1

In all washing Lines, unified maintenance is done.

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

Para 1009 of Chg manual Indicate quantum of rejection in addition to observation

27.1 Wheel and axle Para 1009 a of Chg manual Record of detachments checked in Sick Line and 301 coaches were marked sick for wheel defects from Oct,11 to March,12, details of which are as under: Primary Rakes: 271 Secondary Rakes: 30

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


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


iii) Guidelines for wheel inspection in open line depots (Ref RDSO CMIK003)

In addition to normal checks exercised on wheel condition during primary/secondary maintenance of coaches, a detailed inspection of wheels should be done when the coaches are received in sickline for attention for either schedules or out of course attention. The wheels sets shall be inspected for the following conditions and action taken as indicated for each condition:


a) Shattered Rim Yes.

b) Spread Rim Yes.


SN Item Clause Observation c) Shelled Tread Yes.

d) Thermal Cracks Yes.

e) Heat checks Yes.

iv) The defective wheel should be sent to workshop for repairs after entering in the maintenance card details of the work order and date of dispatch to workshop.


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


27.2 Roller Bearing Axle Boxes Para 1009 b of Chg manual

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

This is being followed. Record of detachments checked in Sick Line and 32 coaches were marked Sick for Roller Bearing defects from Oct,11 to March,12, details of which are as under: Primary Rakes: 30 Sec. Rakes: 02

ii) Care should be taken not to keep a coach fitted with roller bearing stationary for a long time. Coaches grounded for a long time should be shunted up and down at regular intervals. Coaches fitted with roller bearing should be checked to ensure that :- i) No wash basin drain hole / discharge pipe is directly above the axle box ii) The front and rear covers of the axle boxes are not damaged, cracked or loose iii) Clearance between axle box and wheel is such that the axle box does not bind against the wheel. iv) Brake gear is properly adjusted to avoid possibility of brake binding


27.2.1 Axle box is examined for grease oozing out from rear cover and corrective action is taken. Concerned shop needs to be advised for necessary corrective and preventive action.


27.3 Axle box temperature measurement by non contact type temperature measuring instrument during rolling in examination:

Carriage Dte/RDSO letter no. MC /AB dtd 21.08.09


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


ii) If temperature is found above 800 C, the

affected coach will be detached. This is being followed.

It was reported that even below 80 Degree Centigrade if any coach is found suspected in comparison to other Axle Boxes then also detachments are done. One such detachment was done in Train No. 12391 Shramjeevi Express on 08-



03-12 wherein axle box temperature found to be 65 Degree Centigrade whereas temperature of other Axle Boxes was from 23 to 25 deg C and the rollers found deformed when examined in Sick Line.

27.4 Minimum permissible wheel diameter in ICH design BG coaches.

RB letter no. 92/M (C)/137/2 Vol V dtd 25.1.11

i) Shop issue size of wheel set should be 837 mm


ii) Condemning diameter of the wheel in service, measured at a distance of 66.5 mm from the outer face of the rim shall be 825 mm.


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

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


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


28.2 Maintenance of brake gear rigging should be given as per guidelines circulated by ED/Carriage /RDSO vide letter no. MC /ICF/B/D dtd 03.07.09


29 Other items:

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

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

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

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

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

29.3 FAC amenities are provided as per guidelines circulated vide DG/Carrg/RDSO’s letter no. MC/CB/AC/BG dtd 28.04.10

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

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

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

wall Bottle and tumbler holder

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

These are being followed partially due to availability constraints.

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.

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


ii) Rolling – in and rolling- out examination may also be conducted for each of the Duronto trains at the respective operational halts and also at the terminals during the journey. Such safety examinations of the Duronto trains may be periodically super checked at the level of officers.


Rolling-in-examination of all Duronto Trains is carried out in the depot.

iii) Short distance Duronto with only AC / Non AC chair car may be permitted to run on the extant pattern for Shatabdi trains with


All Duronto Trains are given Secondary Examination.


SN Item Clause Observation 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.

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

RCF’s letter no. MD 22.151 dtd 09.02.10


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

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


29.7 Analysis of sick marking and en-route coach detachment

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

This is being followed. 09-10 : 1978 10-11 : 2278 11-12 : 2013

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


iii) Whether en-route coach detachment is investigated and corrective & preventive action taken. Details of en-route coach detachment for last 3 years to be collected with investigation report.


29.8 Facilities for pit line and sick line attention

CAMTECH Maintenance

Manual for BG Coaches of

ICF design,

1st correction slip–

CAMTECH/2002/M/C/ CMM/1.0/CS-01(07.2006)

i) Facilities available as per CAMTECH guidelines as detailed in annexure – I to be observed.

Partially available. 1. The pits available at

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

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

3. Gauges of Rake test rigs are not calibrated.


SN Item Clause Observation 30 Passenger satisfaction

30.1 OBHS & escorting of trains

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

11 trains are covered

under OBHS.

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

In 08 Nos. Rajdhani Trains (Train No. 12205, 12236, 12424, 12425, 12436, 12440, 12442, 12454 )

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

11 Nos. Trains (Train No. 12002, 12004, 12005, 12011, 12013, 12015, 12017, 12029, 12031, 12037, 12402)

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

02 Nos. (Train No. 12497 Shan-e-Punjab and 12428 Rewa Express)

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

Average PSI remains above 85% for all trains covered under OBHS. No record of verification of

manpower deployment for

OBHS and completion

thereafter could be seen at

DLT complex. The daily

diary also does not carry

any detail.

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.

Passenger opinion is taken on Opinion Book available with on board staff. Penal action is being taken on complaint. Shri V.K. Thukral, SSE Incharge, Rajdhani is maintaining passenger feedback in a very novel form, in addition to the prescribed norms. For every Rajdhani train, a visitors’ book is maintained and passengers’ feedback is obtained therein.

30.3 Whether depot has system to analyse passenger complain and takes corrective action. Passenger complains for last three years with action taken to be submitted.

This is being followed. Passenger complaints in the last three years, inclusive of cleaning, linen, OBHS and pest control are as follows: 09-10 : 653 10-11 : 1026 11-12 : 205

30.4 Whether depot has facility for mechanised cleaning of coaches. List of equipments and nos of rakes covered in every month

Mechanized cleaning of coaches is outsourced for all trains except 09 Nos.


SN Item Clause Observation to be submitted. Shatabdi Trains wherein it

is being attended partially. 30.5 Whether depot has facility for upholstery

and carpet cleaning either through in-house or through contract. Efficacy of cleaning to be observed.

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

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

Yes

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

Yes

30.8 Compliance of CRB letter to GM for sustainable image makeover of the Railways:

CRB DO no. 2011/ER/6018 dtd 28.07.11

i) Cleanliness of coaches:

a) Ensure high standards of cleanliness in the coaching maintenance depot particularly in the washing line area.

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

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

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

c) Sustainable garbage collection and disposal system

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

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

Pit and Drains cleaning is outsourced and efforts are made to ensure that the drains are cleaned to avoid water logging but due to improper slope, water logging is found in DLT Washing Line No. 5, Washing Line No. 5 of Shatabdi Complex and Washing Line No. 7 & 8.

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

Fumigation is not carried out in the depot.

f) Monitoring the functioning of OBHS and CTS scheme.

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

g) At the Zonal / Divisional level, SAG / Selection grade officers by name and designation may be put in –charge of important Mail/Express trains under “Own your train scheme (OYTS)” with responsibility being taken by the officers for the areas for which they have been nominated.

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


SN Item Clause Observation 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.

Adequacy of Linen in terms of quality and quantity was of a reasonable standard, with a definite scope for improvement in inspection standards. On 15/04/12, 2 packets from two different bags were checked at random and bed sheets were found in damp condition. Shri Shashi Bhushan, JE informed that he had inspected and returned few bags to the laundryman on that day’s inspection of washed linen. However, related Memo no. 72, dated 15.04.12 was seen which had no posting in this regard. System of inspection of washed linen and accountal of return of dirty linen received after washing was not found to be foolproof.

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

Work of cleaning of Linen is outsourced.

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

The activity is outsourced and streamlined.

31 LHB coach attention:

31.1 Periodicity of periodic overhauls (POH) in designated workshops is being followed.

Schedule Periodicity

IOH (Shop Sch I) 18 months / 5 lakh Km

POH (Shop Sch II)

3 yrs/ 10 lakh Km

POH (Shop Sch III)

6 yrs / 20 Lakh Km

RB’s letter no. 95 /M (C)/ 141 (LHB) dtd 22.08.06

Periodicity of POH is being followed.

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

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

Primary and secondary springs Disc brake attention

Alsthom manual and OEM manuals

Attention to components is being given as per ALSTOM/OEM manual. At DLT Complex, Coach no.LWFCZAC 06907- Dates of D3 and D4 are filled up in the register ( Schedule register). The work evidence is not seen anywhere. Sh. Kharag Singh, SSE/SL/DLT informed that the activity is


SN Item Clause Observation CDTS (Controlled discharge toilet

system) not being carried out in the Sick line. D2, D3 & D4 are all shown on 09.04.12. D3 and D4 activities are only being seen at the washing line to the extent possible. Sr. CDO informed that due to non availability of spare coaches, in view of large no. of coaches on POH account, it is not possible to bring coaches to sickline for D4 attention. At Rajdhani complex, Coach no.10890 - Dates of D3 and D4 are filled up in the register (Schedule register). The work evidence is not seen anywhere. Shri V.K. Thukral, SSE/Incharge Rajdhani Complex informed that the activity is not being carried out in the Sick line.

31.3 Wheel sets and CTRB attention at depot:

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

Para 1009 a (iii) of chg manual

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

ii) Wheel profile should be checked with Tyre defect gauge to ensure the profile dimensions are within the permissible limits. Coaches with wheels having thickness and profile worn below condemning limit should not be allowed to continue in service and the coach should be marked sick for change of wheels in the sick lines.

Para 1009 a (i) of chg manual

Instructions are being complied with.

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

Para 1009 a (ii) of chg manual


iv) System is available for rolling – in examination at terminating station and axle box temperature is measured with non contact type temperature measuring equipment and corrective action taken for wheel sets with high temperature.

Carriage Dte/RDSO letter no. MC /AB dtd 21.08.09


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

Wheels Set with wheel dia. less than 865mm are received in the depot from Workshop but condemning limit is being taken care of during maintenance.


SN Item Clause Observation vii) Presently the refurbishing/overhauling of

LHB bearing is being done at an interval of 1.2 million km. To ensure attention of CTRB’s as well as UST of axle, depot should have proper identification of wheels sets. In case wheel sets are interchanged then traceability of wheel sets and timely attention of wheel sets exist in the depot.

Instructions are being followed in the depot.

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

Problem of short supply of LHB Type Wheel Sets is being faced in the depot.

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.

Instructions are being followed.

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


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


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


31.4 Phonic wheel/Speed censor OEM guidelines

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

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

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

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

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

Procurement of these items is being done by Store depot. Phonic wheel supply is from OEM only, however, speed sensors had been received from sources other than OEM but from RCF approved sources. Now, specifications have been redrafted at HQ for procurement only from OEM.

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


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

OEM guidelines This is being followed.


SN Item Clause Observation 31.6 Earthing Device OEM guidelines

Earthing device of most of the coaches should be functional. It consists of non ferrous components (approx 2kg weight) which are theft prone. Loose fasteners, in case of theft attempts for non-ferrous items, mounted inside of axle box housing, can damage CTRB.

Out of 242 Coaches checked in the depot, following observations recorded: (i) Nos. of Units checked:

484 Units. (ii) Nos. of Units found

deficient: 355 Nos. (iii) Units found functional:

102 (iv) 27 Nos. Units found

with deficiency of Earthing Wires.

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

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

Junction box in broken/damaged condition.

Nil

31.7 Disc brake attention: OEM guidelines

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

This is being followed. Scarcity of brake pads was highlighted by Sr.CDO/NDLS

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


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

In-house attention is being given.

31.8 Whether guidelines circulated by RDSO for CBC equipped coaches are being followed.

Carrg Dte/RDSO letter no. MC/BLB/CBC dtd 22.05.08

Yes

31.9 Attention of side buffer:

Length of side buffer of CBC equipped SLR (FV & LV) is maintained to 635 mm as per RDSO drawing no. SK - 98145

Carrg Dte/RDSO letter no. MC/BLB/CBC dtd 17.02.08

Yes


Annexure - I

Standard facilities in Carriage Maintenance Depots

(Ref : CAMTECH Maintenance Manual for BG Coaches of ICF design,

1st correction slip– CAMTECH/2002/M/C/CMM/1.0/CS-01(07.2006)

Classification of depots

Classification No. of coaches based

Minor Depot Below 100

Medium Depot 100 to 250

Major Depot Above 250

Machinery and Plant

Description Minor

Depot

Medium

Depot

Major

Depot

Observation

U/floor wheel lath - - 1 1

Whiting jacks (5 Nos.) - 1 set 1 set 3

EOT crane 20T - - 1 4

Coach Shunter - 1 2 1

Welding Plant 1 2 4 12

Gas Cutting Equipment 1 2 2 2

Vacuum Exhauster 1 2 2 0

Air Compressor 30 cfm 1 2 2 6

Portable Vacuum Testing Equipment - 1 1 0

Portable Air Compressor - - 1 3

2T Tram beam hoist 1 1 2 0

Sewing machine - 1 1 4

Truck 10T - - 1 0

Light Coml. Vehicle 1 1 1 1

Fork lift truck - - 1 4

Lister truck 1 1 2 4

Car Washer - 1 1 0

Portable Trolley Light 2 4 0

Cotton waste soaking plant 1 1 1 0

Wood cutting saw machine - 1 1 3

Hand shearing machine - 1 1 4

Portable Furnace 1 1 2 0

Centre Lath - - 1 1

Bogie Manipulator - - 1 0

Ultrasonic Testing Apparatus 1 1 1 0

Tool post Grinder - 1 1 1

Vacuum Cleaner 1 2 3 2

Pressure Jet Cleaner 1 2 4 4


Description Minor

Depot

Medium

Depot

Major

Depot

Observation

Tools

a. Pneumatic Hand Tools 01 Set

i. Grinder 1 1 2 02 Set

ii. Drill 1 1 2 6

iii. Chipper / Buster - 1 2 0

iv. Riveter - - 1 0

b. Electric Power Tools 0

i. Pop Riveting Gun - 1 1 0

ii. Drill - 1 1 0

iii. Bolt Tightner - - 1 0

c. Hand Tools As required

02 Sets in Tool Room,

One Set in Centralized

Tool Room and with

Every maintenance gang

d. Test Bench (LHB CDTS)

e. Test Bench (WSP)

02 (One Each in Ajmeri Gate Sick Line and DLT Sick Line) 01 in Sick Line

i. Water Tank Test Rig - 1 1 0

ii. D.A. Valve Test Bench - 1 1 0

iii. Vac. Cyl. Test Bench - 1 1 0

iv. Slack Adjuster Test Bench - 1 1 1

v. DV Test Bench - 1 1 1

vi. Air brake single coach test rig - 1 1 3

f. Office Equipment

i. Computer system 1 1 1 5

ii. Plain Paper Copier 1 1 2 1

iii. Telefax 1 1 0


Annexure - II

Emergency materials required for platform (C&W) office

Sl. Items Required Observation

1 Screw Coupling complete ( 75 t ) 1 no. 01 No.

2 Draw Hook ( ICF- Enhanced capacity) 1no. 01 No.

3 Draft cotter with 'U' pins 1no. 01 No.

4 Draft link complete 2 sets 01 No.

5 Equalizing Stay rod with pins ( Non-modif. &

Modif.) 1 set each

01 No.

6 Anchor link with securing studs 1 set 01 No.

7 Truss Bar Hanger with Pins & Cotters 2 sets 02 Sets

8 Bolster suspension Link (Stirrup Link) with Pins &

Stones 2 sets

02 Sets

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

Pins 2 sets

01 No.

10 'O' Ring 2 nos. -----

11 Grease Servogen 4 kgs. 04 Kg

12 Adaptor (BF+FP) for by-passing 2 sets 02 Nos.

13 Angle cock 2 nos. 02 Nos.

14 Dummy Flange (A/B) 2 nos.

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

16 Teflon Tape 1 no. 01 No.

17 Portable Air Pressure Gauge 1 no.

18 Pressure Gauge BP & FP 2 each 02 Nos.

19 BP & FP Air hose 2 each 02 Each

20 Guard Emergency Application Valve 2 nos. -----

21 Wooden Plug (various sizes) 10 nos. 36 Nos.

22 Wooden wedge 4 nos. 04 Nos.

23 G.I. wire Adequ. Qt. Yes

24 Buffer bolts (20x120 mm.) 8 nos. 08 Nos.

25 Push cock 5 nos. 04 Nos.

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

27 Slide wrench, Pipe wrench-24'' 2 nos 01 No.

28 Hydraulic Jacks 2 sets 01 No.


Annexure – III

Details regarding coaching depot

Depot name and division: New Delhi Coaching Depot

1. Coach Holding

Mail/Expresses coaches with conventional coupling 105

Mail/Expresses coaches with CBC coupling 35

Rajdhani coaches (conv) 117

LHB coaches (Rajdhani/Duronto) 150

Shatabdi Coaches (conv) and IRY 70

Shatabdi coaches (LHB) 139

Passenger coaches ---

OCV’s ---

Grand Total 616

2. Maintenance attention of at depot

PM of Mail/Expresses train with secondary attention at other end 11

PM of Mail/Expresses train with round trip attention at other end 12

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

Total PM attention at depot: 23 Trains (Max. 17 Trains

per day)

Total SM attention at depot: 23 Trains (Max. 17 Trains

per day)

Total Round trip attention at depot: 24 Trains (Max. 22 Trains

per day)

3. Pit line attention

24 coach pit with catwalk and high pressure water jet

facility/watering facility at per CAMTECH’s guidelines

Available in Shatabdi

Complex only, however

coach capacity is less than

24 Coaches.

24 coach pit facility with catwalk 09 Nos.(W/L No. 9 to 12 and

DLT-1 to DLT-5)

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

be collected)

05 Nos. (W/L No. 3 to 8 )

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

04

Nil

Compressed air with reservoir and Air dryer/moisture trap facility

with test rig (RTR)

Air Dryer available at DLT

and inbuilt Air Dryer in the

compressor in NDLS area.

Facility for welding at Yard attention Welding facility available at

Washing Line No. 3 to 5 and

DLT-1 to DLT-5

Night maintenance facility with overhead/pit light as per

CAMTECH’s guidelines

Overhead lights available in

the Washing Lines but Pit

Lights not available.


4. Sick line facility (Ajmeri Gate as well as DLT Sick Line )

Ajmeri Gate DLT

Coach lifting facility with overhead crane 02 Coach 02 Coach

Coach lifting facility with JMP jack/hydraulic jack 04 Coach

Total coach accommodation

With pit attention Without pit attention

45 Con or 41 LHB

Type

16 Coaches

29 Coaches

14 Con Coaches

05 Coaches

09 Coaches

Facility for compressed air with test rig (SCTR) 02 Nos. 01 No.

Availability of hydrant water for overhead tank

attention

Nil Nil

Welding facility Available in shed. Available in Washing

Line and Sick Line

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

night) as per CAMTECH’s guidelines: Lighting arrangement is not proper in some of the PF. For

improvement in lighting arrangement, work has been sanctioned under DRM’s Power in works

programme-2011-12.

6. Availability of staff for coaching maintenance as per Yard stick: Shortage of staff and supervisor

was highlighted by Sr.CDO.

7. Training status of supervisor and staff –As on 31-03-12, no supervisor is overdue for refresher

training whereas as out of on Roll strength of 617 Technicians, 487 Technicians are overdue for

training.

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

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

9. Availability of coaches as per rake link with maintenance spare: Number of LHB coaches in

workshops have gone up.

10. Bottlenecks / limitations of system / depot: Slope of Drains in Washing Line No. 5, 7, 8 and DLT

Washing Line No. 5 is not proper and problem of water logging is being faced which is major hurdle in

carrying out maintenance of undergear smoothly.

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

instructions are being complied with during maintenance.

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

Documents

Quality Audit report Of Coaching Depot New Delhi, N Rly Report …rdso.indianrailways.gov.in/works/uploads/File/Quality... · 2019-10-17 · in carriage depots on divisions where