Quality Audit report Of Coaching Depot Santragachi, SE Rly

Quality Audit report

Of

Coaching Depot

Santragachi, SE Rly

Report no. 33/2012

APRIL 2012

( Audit is done by QA Mech Dte of RDSO )

Page 1 of 38 Coaching depot – Santragachi, SE Rly April 2012

Quality audit Report of Coaching Depot, Santragachi, SE Railway

1.0 Introduction

Railway Board vide letter no. 2012/M (W) 814/5 dated 20.3.12 has instructed

RDSO / Zonal Railways to conduct quality audit of coaching depots and

workshops. QA (Mechanical) Directorate has been assigned to carry out audit

Santragachi depot.

1.1 Audit team - S/Shri M A Alam, Director/I&L/Kolkata, S Bose, AIE/I&L/Kolkata

and T K Indu, JE/I&L/Kolkata.

1.2 Date of audit - 06.04.12 & 14.04.12

1.3 Escorting officers from depot - Sri G A Jillani, Area Manager/Santragachi,

Sri Tapan Monada, DME/SRC, Sri R L Paul, ADME/SRC, Sri Rahul Roy,

SSE/Technical Cell and concerned SSE/C&W/SRC.

1.4 Scope of audit - Primary maintenance of coaching rakes -under gear

attention (pit attention) and rolling–in examination of terminating trains, coach

cleaning, fitment of passenger amenities items, schedule attention of coaches

( POH, IOH, Schedule A and Schedule B), pest control management in AC

and Non-AC coaches, detachment of coaches (primary, secondary and en-

route) and its analysis, maintaining records– DDR(Damage Deficiency

Register), feedback/complaint and action taken, linen management and

availability of Stores & its management.

After audit, Area Manager/SRC and his team have been briefed about

observation noted during audit.

2.0 Brief about visit

Santragachi coaching depot, South Eastern Railway is one of the largest

coaching depot with holding of 1419 coaches (249 AC coaches and 1099

Non AC coaches) and is a major coaching depot of South Eastern

Railway.

Total 6 deep pit lines with catwalk as per CAMTECH design, 9 deep pit

lines without catwalk and 9 stabling lines are available to carry out 38

primary maintenance, 11 secondary maintenance and 15 round trip

maintenance of important Mail/Express trains such as Chennai

Coromondal Express, Chennai Mail, HWH – Yaswantpur Express, HWH-

Mumbai Mail, CSTM Duranto, Yeswantpur Duranto, HWH –Puri Express

and other important Mail/Express trains to Southern Railway, ECoR and

CR.


During two days of audit, items as per scope of audit have been checked.

Relevant records have also been checked. Infrastructure availability in the

coaching depot and planning of inputs has been studied. The escorting

officers and supervisors have given all assistance to audit team and

escorted the audit team during audit.

3.0 Strengths

3.1 Depot is carrying out maintenance of CDTS, fitted in LHB coaches through

in-house and 93% CDTS are working. Spares are procured through OEM.

3.2 Supervisors and staffs are trained. Depot has good safety performance and

there is no derailment / accident on C&W account.

3.3 Modification work of BP/FP pipe line has been continued at the buffer end of

LHB Generator car to avoid damages of ferrule joint of BP/FP angle cock due

to cattle run over en-route which has been approved by CME/SER. This

modification has been completed in 5 coaches and partially completed in 4

coaches. Further, modification in remaining 4 coaches is planned to be

completed by May’2012.

3.4 Flex Destination board: All rakes (4 rakes) of HWH-YPR Exp and 1 rake (out

of 6 rakes) HWH-Chennai Rakes are completed. Rakes of Ahmedabad Exp &

Mumbai Mail have been planned for fitment of Flex Destination Board.

3.5 Catering service tables have been provided in all AC coaches of all the three

rakes of YPR Duronto Express as there was complaint regarding keeping of

meals trays on the floor beside the toilets in the HWH-YPR Duranto train

before serving to the passengers. Further, catering service tables has also

been provided in all SWGSCN coaches of YPR Duronto Exp.


4.0 Weaknesses

4.1 Depot had provided LED destination board in 92 coaches of HWH –

Yeswantpur Expr (12863/12864) in 2009-10. Connection for LED destination

board had been disconnected by Electrical Department in Feb 2010. LED

destination boards are not working presently.

4.2 Depot has awarded mechanized cleaning contract to M/s Eureka Forbes to

carry out mechanized cleaning in 26 M/E trains (422 coaches). As reported by

depot, performance of firm is very poor. Regular deduction as per contract

provision is being done but response of firm is very poor. Due to inadequacy

of contact implementation, quality of cleaning is suffering. Regular monitoring

is done by depot officials to ensure quality of cleaning.

4.3 Store for linen handling is inadequate. Depot has a total requirement of

10,000 packets per day. Mechanized washing is being done through

outsourcing. However, all items after receipt are kept inside the store and

checking / segregation of bad linen is not adequate. FIFO is not applied for

washed and new linen due to congestion of linen store.

4.3.1 Blankets are dry cleaned at two months interval against recommended

interval of one month.

4.3.2 Curtains are washed at two months interval against recommended interval of

15 days.

4.4 All major Mail/Express trains have not been provided OBHS through contract

and escorting by depot. OBHS have been provided in 3 trains (1 through

outsourcing and two trains by depot). OBHS through outsourcing as per RB’s

guidelines have not been provided in major M/E trains. OBHS contract

already expired on 31.10.11 and new contract has not been placed by Zonal

Railways. Depot has planned for OBHS in total 9 important Mail/Express

trains.


4.5 Feedback system for quality of linen and pest infestations from coach

attendant (CA) is not adequate. CA is not reporting for linen quality and pest /

rodent infestation in every trip.

4.6 Passenger complaints on account of pest / rodent and linen have increased

during 2011–12. Summary of passenger complaints for last three years are as

under.

Yr Pest/ rodent Linen Others Total

09 -10 24 48 129 201

10-11 10 38 122 170

11-12 92 115 355 562

4.7 Pest control is awarded to M/s CWC/Kolkata as per Rly Board’s guidelines.

However, performance of pest control agency to carry out pest control is not

satisfactory. Complaints on account of pest/rodents have increased to 92

during 2011–12 as compared to 10 in 2010–11.

4.8 Depot is carrying out rodent control treatment as per contract’s provision.

Complaints on account of rodent have increased to 68 during 2011 – 12 as

compared to 4 in 2010–11. However, refuses / left over foods from pantry cars

are disposed after arrival of trains in Yard. Refuses of other coaches of train

are also disposed in Yard. The following shortcomings noted for rodent

control-

Garbage collection and disposal system is not adequate. After dry

sweeping of coaches, all refuses are not collected and some splattered

on the pit lines.

Rodent control measure has not been taken for HWH platform area by

Engineering/Medical department. Existing contract is already expired.

Rodent control measure is available for depot area only (carried out by

C&W department).

4.9 Depot is not aware regarding list of safety items published by RB and

following their own list of safety items. Store is congested due to in-adequate

space. Items are not labeled. FIFO is not applied. As reported by depot, due

to improper pathway, it is difficult to handle heavy items and these items (such

as AR, CBC etc) are kept at several locations.

4.10 Passenger amenities in Non AC coaches (GSCN) such as magazine bags,

bottle/tumbler holders and snack tables are missing. As reported by depot,

shop is not providing these items in Non AC coaches.

4.11 Reports of deficiencies/ defects in Rolling Stock (DRS) reports in the proforma

given in Annexure 1.2 of CAMTECH manual are not prepared jointly. On

arrival of the train at the destination station, joint report for deficiency in rolling

stock has not been prepared.


4.12 With existing system, grease oozing out in LHB wheel sets can be checked

from front seal only when front cover is opened. This is being checked during

D2 /D3 schedule as front cover is opened for attention. For checking grease

oozing out at rear grease seal, bottom control arm is to be taken out.

Checking of grease oozing out in LHB wheel sets is not done for rear end seal

at depot.

4.13 Contract for disc brake (including air brake) attention in LHB coaches for KB

makes and FTIL make brake system has not been awarded. Depot is carrying

out maintenance attention of KB and FTIL make disc brake system through in-

house. Brake callipers are not attended at depot.

4.14 En-route detachment of coaches has increased during 2011-12. Summary of

en-route detachment during last three year is as under -

4.15 Record of secondary detachment is not available at depot. Analysis of

secondary detachment is not being done.

4.16 Depot has received 1482 wheel sets and 592 bogies sets from KGP shop

during 2011–12 which is equivalent to 666 coach sets. Total 845 IOH

attention (including newly built coaches) have been given at depot during

2011–12. All wheel sets as per guidelines of Railway Board’s have not

been changed during IOH attention.

4.17 Joint certificates have not been issued for newly introduced train by

Sr.DME/C&W or ARM/SRC and Sr.DOM. Total 11 new trains introduced in

2011-12 and 10 trains introduced in 2010–11. However, joint certificate

covering each clause of mandatory conditions have not been issued at

divisional level.

4.18 The staffs available for cleaning activity are 174 against requirement of 784.

Shortfall has been compensated through outsourcing of cleaning activity.

Total 566 staff deployed for cleaning activity through outsourcing. Manpower

available for under gear examination is 792 staff against requirement of 904

staff. Manpower available for sick line attention is 90 staff against requirement

of 204 staff. There is shortfall of 836 staffs as per Rly Board’s bench marking

norms. Depot has processed staff creation proposal. Coach holding of depot

has increased from 850 in 2006 to 1419 in 2012. However, staff strength have

not increased and reduced due to surrender of post. As reported by depot, 77

& 32 posts surrendered during 2007-08 and 2008 -09.

Yr LHB ICF Total Hot axle case

2009 – 10 - 1 1 1

2010 – 11 1 4 5 2

2011 – 12 - 9 9 7


4.19 Rake maintenance link has a provision of 6 hrs maintenance time for pit

attention at primary end except for HWH–PRR express (12827/12828) in

which clear maintenance time of 6 hrs is not available as per train time table.

Train arrives at HWH PF at 11.20 and depart at 16.50.

4.20 For facilitating inspection of sole bars even spaced elongated holes of

(215x127 mm) are not provided in the turn under of all coaches. Coach no SE

058412, SE 968028, SE 988035 have been checked in sick line and found

that these coaches are not provided with elongated holes of 215x127 mm

size.

4.21 INFRASTRUCTURAL CONSTRAINTS OF SRC Depot –

Lack of direct admission facility at WCD: There is a lack of direct

reception in washing cum departure Yard due to which all trains are

being received at reception yard and further placed at NCG & WCD

which necessitate multiple shunting movement.

Lack of dispatch and reception facility from Reception – Yard to

Shalimar.

Only 2 out of 9 lines in R- yard are designed for long composition (23/24

coaches). There is only one shunting neck to handle the rakes. The

yard is not provided with catwalks and is having overhead wires which

require multiple placements for exterior cleaning.

Total 21 trains are to be dispatched from 15 to 23 hrs. while in washing

–cum departure yard, there are only 03 lines of 24 coach capacity. Not

more than 2 rakes can be tackled in WCD for attaching and detaching of

coaches.

Stabling facility is available for 123 coaches while requirement is for 160

coaches.

Connecting pathways are not available for movement through FLT/ lister

truck.


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)

Location: Santragachi

Date of audit: 06.04.12 & 14.04.12

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

Periodicity of POH as per Railway Board’s guidelines is followed. ICF & LHB coaches are given POH attention at LLH shop. Status of POH attention during 2011 - 12 is as under:

AC 132

NAC 498

Total 630

Overdue POH as on 01.04.12 is nil.

2 Maintenance schedules to be followed in coaching depots

To maintain coaching stock in good condition, the following maintenance schedules are prescribed to be carried out in carriage depots on divisions where rake has been based for primary maintenance.

112(a) of Chg. Manual an Correction slip 5 for coaching maintenance manual issued in 2008 RB letter no. 2007/M ( C)/141/1 dtd 26.09.08

SRC Depot/HWH has a bare holding of 1200 coaches and total holding of 1419 coaches (including maintenance spare and traffic spare). ICF coaches – 1098, ICF design CBC coaches – 171, LHB design CBC coaches - 66, Hybrid design CBC coaches - 66 & Shatabdi (Conv) – 18. Schedule A & B attentions in rake are being carried out as per recommended frequency for ICF coaches. LHB coaches are also attended as per recommended frequency. (D2 schedule at one month interval and D3 at six month interval). IOH attention of ICF design coaches are given at depot. Bogies are overhauled at depot and shop is also supplying overhauled bogies to depot. Overhauled wheel sets are supplied to depot by KGP shop. Attention given during 2011 -12 is as under: Average A schedule / month: 716 Average B schedule/ month: 314 Average IOH attention/month: 70 New sick line at SRC depot has carne facilities of 25T – 02 nos. and 5T – 01 no. and coach lifting capacities of 8 coaches. Old sick line has no crane facility with coach capacity of 6 coaches under shed. A/C shed NPL – 1 & 2 with covered

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

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

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.


SN Item Clause Observation For IOH attention of newly built coaches, guidelines as circulated vide RB’s letter no. 2007/M ( C)/141/1 dtd 06.08.09

shed is available for attention of AC coaches with capacities of 4 coaches. Lifting at depot is being done by JMP Jacks in old sick line and with lifting tackle in new sick line. Total 18 nos. jacks are available at sick-line. Overhauled bogies are supplied to depot in BRN wagon and arrived / dispatched as separate load. Newly built coaches (ICF design) are attended depot as per Board’s guidelines. Overdue IOH coaches: NIL Depot has received 1482 wheel sets and 592 .bogies sets from KGP shop during 2011 – 12 which is equivalent to 666 coach sets. Total 845 IOH attention (including newly built coaches) have been given at depot. All wheel sets as per guidelines of Railway Board’s have not been changed during IOH attention.

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. The depot is carrying out the following attention at depot:

Mail Express trains

PM with RTM at other end 22

PM with SM at other end 12

RT attention 15

SM attention of other base 11

Intercity trains

PM withy round trip attention

4

Total attention 64

Out of 64 maintenance attention (PM,SM and RTM), attention of 16 trains (PM – 9, SM-4 & RT – 3) are given at Padampukur (adjacent to SRC) under SRC control.. Total 19 coaches are missing over Foreign Railways. These coaches returned to base depot when due for POH.

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

7.1 All trains must be examined by the mechanical train examining staff before despatch to ensure all coaches are in fit condition without rejectable defects.

107 a (i) of Chg. Manual

This is being followed. All trains are examined by C&W staff before despatch.

8 Terminating Examination of Passenger Trains – Rolling in examination.

107 b of Chg. Manual

Rolling–in examination is being carried out at HWH. Deployment of staff have been checked during audit and found only 2 men deployed for


SN Item Clause Observation

rolling-in examination.

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

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

Site has un-obstructed view of under gear from both side.

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

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

Lighting arrangement for rolling–in examination is available except for PF-17, PF -21 & PF-23) at HWH station. ARM/SRC has requested DRM/HWH for arranging lighting arrangement and one room for keeping tool boxes of TXRs..

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 Record maintained for rolling in examination is not adequate. Separate TXR’s maintain their register for rolling in examination and record of all rolling –in examination of all trains at a glance can not be perused as records are kept by them in their locker. Format for recording rolling –in observations are not available. During inspection on 14.04.12, it is observed that temperature recorder available with TXR is not working. All temperatures of axle boxes are not recorded. Only high temperature of axle box in a coach is recorded. In addition during audit check on 14.04.12, rolling-in staffs were found standing at site but not carrying out rolling-in examination of East Coast Express during arrival at PF.

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 Axle box temperature is measured with non contact type temperature measuring device. 04 nos. non-contact infrared temperature measuring devices are available at PF. During check one no found not working.

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

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

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

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

This is being ensured.

9.1.1 Primary End

i) The brake gearing should be

properly adjusted including the

slack adjuster ‘A’ dimension & the

brake cylinder stroke to ensure

100% brake power

-do- ICF Coaches have been provided with BMBC. Piston stroke is adjusted to 40 mm during primary maintenance.

ii) Brake blocks should be changed -do- This is being ensured.


SN Item Clause Observation in bogie sets only

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

-do- All AC coaches are provided with passenger amenities items. However, passenger amenities in Non AC coaches such as magazine bags, bottle/tumbler holders and snack tables are missing. As reported by depot all passenger amenities items are not provided in Non AC coaches during POH. Snack table in NAC coaches are provided directly over L.P sheet and this worked out during service.

iv) Intensive cleaning of coach toilets and lavatory.

-do- This is being ensured.

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

-do- Clear maintenance time of 6 hrs on the pit is available as per train schedule except for HWH –PRR express (12827/12828) in which clear maintenance time of 6 hrs is not available as per train time table. Train arrive at HWH PF at 11.20 and depart at 16.50.

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

-do- SRC depot has the following pits and stabling line for rake maintenance:

24 coach pit with catwalk and washing apron

06

24 coach pit facility without catwalk

01

Less than 24 coach pit facility without catwalk

08

Stabling line with 24 coach facility

3

Stabling line with less than 24 coach facility

6

09 deep pits at SRC/Reception Yard are non standard without catwalk. Only 6 pits have been constructed as per CAMTECH design (4 at NCG and 2 at Padampukur). 07 nos. RTR are available for air brake testing. High pressure jet machines are used for coach washing and toilet cleaning by contractual agency (total 36 trains have been outsourced). Cleaning of balance trains are carried out by depot and hydrant line is used for coach washing and toilet cleaning.

vii) Adequate gang strength with proper supervision

-do- The staffs available for cleaning activity are 174 against requirement of 784. Shortfall has been compensated through outsourcing of



cleaning activity. Total 566 staff deployed for cleaning activity through outsourcing. Manpower available for under gear examination is 792 staff against requirement of 904 staff. Manpower available for sick line attention is 90 staff against requirement of 204 staff. There is shortfall of 836 staffs as per Rly Board’s bench marking norms. Depot has processed staff creation proposal. Coach holding of depot has increased from 850 in 2006 to 1419 in 2012. However, staffs strength have not increased and reduced due to surrender of post. As reported by depot, 77 & 32 posts surrendered during 2007-08 and 2008 -09 Adequate staffs are not available for safety maintenance.

9.1.2 The Other End

i) Whenever the lie-over is more

than 2 hours at the platform or the

rake is stabled in the yard, the

rake should be locked and

positive security should be

provided

-do- This is being ensured at other end.

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

-do- This is being ensured at other end.

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- Joint certificates have not been issued for newly introduced train by Sr.DME/C&W or ARM/SRC and Sr.DOM. Total 11 new trains introduced in 2011- 12 and 10 trains introduced in 2010 – 11. However, joint certificate covering each clause of mandatory conditions have not been issued at divisional level.

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

108 of Chg. Manual and Policy circular no. 4

Rake maintenance link has provision of 6 hrs maintenance time for pit attention at primary end except for HWH –PRR express (12827/12828) in which clear maintenance time of 6 hrs is not available as per train time table. Train arrive at HWH PF at 11.20 and depart at 16.50.

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

Attention is given for rake cleaning, amenities attention and watering at pit line.

12 Washing and cleaning of 109 of Chg.Manual


SN Item Clause Observation coaches

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 Depot is using solution for cleaning as approved by RDSO. Cleaning solution is provided by contractual agency for the coaches undertaken for cleaning activity 26 trains (422 coaches). Total 181 coaches are cleaned departmentally with chemical provided by depot. In addition, 50 trains are cleaned through contractual agency with chemical provided by depot. Dry sweeping of 45 coaches are carried out at HWH PF for round trip attention.

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 Wooden wedges are applied to avoid rolling down of rake and red protection board is applied.

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

109 (b) of Chg.Manual Coaches of 12842 / 12839 have been checked during audit on 06.04.12. External cleaning is found satisfactory

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

109 (c) of Chg.Manual Coaches of 12842 / 12839 have been checked during audit on 06.04.12. Cleaning of toilet is found satisfactory.

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 Coaches of 12842 / 12839 have been checked during audit on 06.04.12. Internal cleaning of AC coaches is found satisfactory.

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

109(e) of Chg.Manual Coaches of 12842 / 12839 have been checked during audit on 06.04.12. Internal cleaning of GS and SLR is satisfactory.

12.7 Cleaning of buffers and screw couplings

109(f) of Chg.Manual

(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 ensured.

(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 ensured.

13 Conditions required for maintenance of 24 coach trains

110 of Chg.Manual Total 5 PM trains are 24 coach length trains and 1 SM train is 24 coach


SN Item Clause Observation (Railway Board’s letter No.98/M(C)/137/19 Pt.I dt.28.7.99 & 5.5.2000

length trains.

13.1 Infrastructural requirements 110(a) of Chg.Manual

(i) 24 coach length fully equipped pit

line.

110(a)(i) of Chg.Manual SRC depot has 6 (six) deep pits with 24 coach facility.

(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 Cleaning is being done with high pressure jet machine by contractual agency.

(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 Depot has not studied problems of en-route coach watering due to insufficient stoppage time. There are 12 cases of passenger complaints due to non-availability of coach water.

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

110(a)(iv) of Chg.Manual Total 7 nos. RTR are available for air brake testing. Air pressure is 10 – 7.5 Kg/cm

2.

Total 6 Compressors of 200 CFM (2 nos), 350 CFM (2 nos)., 360 CFM (1 no.), and 325 CFM (1 no.) are available at depot.

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 This is being ensured

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

110(b)(ii) of Chg.Manual All ICF coaches (Conventional) have been provided with enhanced capacity draw gear and screw coupling (75 T capacities). LHB /Duronto coaches and ICF coaches (with CBC) are provided with H type CBC. Total 303 coaches have been provided with CBC arrangement.

13.3 Maintenance practices and system related requirements

110(c) of Chg.Manual

i) The integrity of the rakes to be

maintained.

110(c)(i) of Chg.Manual Integrity of rake is maintained.

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

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

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

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

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 ensured. RPC 4 has been revised and PM with round trip is permitted up to 3500 Km for 24 coaches’ trains also.

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

110(c)(v) of Chg.Manual This is being ensured. Air brake testing is being done with RTR.

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

110(c)(vi) of Chg.Manual Air flow measuring valve has been


SN Item Clause Observation working order provided in locomotives

vii) Provision of audio visual alarm

system on the locomotive 110(c)(vii) of Chg.Manual

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

111(f)(i) of Chg.Manual Quarterly and yearly attention as stipulated is provided 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

DCP type FE’s are provided as under: AC / SLR – 2 nos each Pantry car – 04 nos. Generator car – 02 nos.

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 C&W department is providing FE’s and wooden wedges in trains. Other equipments are provided by TL, S&T and traffic staff. All items of brake van have been kept in SLR at depot and Almirah is sealed.

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 As reported by depot, Watering stations are TATA and Rorekela. CTS are available at KGP.

17 Deficiency Rolling Stock (DRS) for Coaching Stock

111(i) (i) of

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

Chg.Manual This is not being followed. DRS reports are not prepared jointly.

(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 This is not being followed.

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

Chg.Manual Coaching depot is maintaining coach maintenance history in computer (in Access based software) which is accessible to coaching depot officer


SN Item Clause Observation programme of the coaching workshop.

and supervisors. However coaching workshop is not linked with depot for assessing coach history. During POH, depot is furnishing coach history details to shop in hard copy.

(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 is not being followed.

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. The depot is carrying out the following attention at depot:

Mail Express trains



RT attention 15


Passenger trains


4

Total attention 64

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.

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. However, under gear cleaning is not satisfactory to facilitate examination of under-frame, bogie frame, axle box and springs etc.

19.5 The following items of under-gear 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

113 (e) (i) of Chg.Manual

Oil level in dash pot is checked on monthly basis and oil is filled up on need basis.


SN Item Clause Observation 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.

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. ICF coaches have been provided with BMBC and piston stroke is adjusted to 40 mm by depot during PM.

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 This is being followed.

iii) Door lock handles 113(f)(iii) of Chg.Manual This is being followed.

iv) Tower bolts 113(f)(iv) of Chg.Manual This is being followed.

v) Window shutters should neither be tight nor loose

113(f)(v) of Chg.Manual This is being followed.

vi) Window shutter safety catches 113(f)(vi) of Chg.Manual This is being followed.

vii) Window frame 113(f)(vii) of Chg.Manual This is being followed.

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

113(f)(viii) of Chg.Manual This is being followed.

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

113(f)(x) of Chg.Manual This is being followed.

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 This is being followed.

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

113(f)(xii) of Chg.Manual This is being followed.

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 Depot is maintaining record of PM in DDR. Records for Upper body and under gear are maintained in DDR. All relevant records are maintained for rake wise during PM of rake.

20 Schedule ‘A’ Examination 114 of Chg.Manual


SN Item Clause Observation 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 This is being followed. Record of schedule ‘A’ examination is maintained in printed schedule form.

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 This is being followed. Record of schedule ‘B’ examination is maintained in printed schedule form.

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

This is being followed.

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

b. Painting of lavatories from inside. 115(b)(iii) of Chg.Manual This is not being followed. Attention is given on need basis.

c. Thorough inspection and repairs of brake gear components.

115(b)(iv) of Chg.Manual This is being followed.

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

115(b)(v) of Chg.Manual This is not being followed.

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

115(b)(vi) of Chg.Manual This is not being followed. Attention is given on need basis.

22 IOH attention

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

22.1 Periodicity of IOH attention:

Coach Category

Periodicity

New coach at interval of 12

months in Depot

Rajdhani Satabdi (Conv)

at interval of 9 months in workshop

Mail / Express at interval of 9

months in depot

Passenger at interval of 9

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

During 2011, 845 coaches attended at depot for IOH attention. Overdue IOH coaches: NIL For newly built coaches, RB’s guidelines are followed. Overhauled bogies are supplied to depot in BRN wagon and arrived / dispatched as separate load. Newly built coaches (ICF design) are


SN Item Clause Observation 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

attended depot as per Board’s guidelines. Depot has received 1482 wheel sets and 592 .bogies sets from KGP shop during 2011 – 12 which is equivalent to 666 coach sets. Total 845 IOH attention (including newly built coaches) have been given at depot. All wheel sets as per guidelines of Railway Board’s have not been changed during IOH attention.

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

For IOH attention, coaches are detached from rake.

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. IOH coaches are attended at depot including unde-gear attention and upper body attention as well as air brake system attention.

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 Bogies are overhauled during IOH attention at depot. Facilities for magnaflux of hangers have been developed at depot. In addition, shop is supplying bogies to depot for IOH attention.

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

117(a)(iii) of Chg.Manual Attended at depot on condition basis during IOH attention of coaches..

22.8 Polishing of the polished surfaces.

117(a)(iv) of Chg.Manual This is not 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 Attended at shop during overhauling of bogie. However, during IOH attention at depot, shock absorber is attended due to oil leakage and other physical damage only.

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 This is not being followed.

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 not 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 under.

117 (d) of Chg.Manual For facilitating inspection of sole bars even spaced elongated holes of (215x127 mm) are not provided in the turn under of all coaches. Coach no SE 058412, SE 968028, SE 988035 have been checked in sick line and found that these coaches are not provided with elongated holes of 215x127 mm size.

22.16 Special attention should be taken for the following:-

117(e) of Chg.Manual

i) Pocket between sole bars and turn under 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 This is not being followed.

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 Records of Schedule A, B attention are maintained in standard format. For IOH attention at depot, record is maintained in standard format for upper body and under gear attention. During audit check on 14.04.12, it is observed that schedule form for IOH attention has not been signed by concerned supervisor for IOH carried out on 12.04.12.

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 LHB coaches have been provided in Duranto Express (HWH –CSTM and HWH-Pune). Hybrid coaches have been provided in Duronto Express (HWH – Yeswantpur). Conventional EOG ICF coaches have been provided in Digha Duranto Express.

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

118(c) of Chg.Manual IOH attentions of LHB coaches are carried out in LLH shop.

23 Linen management


SN Item Clause Observation 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.

C&W department/SRC is carrying out complete activity of linen management. However, distribution is being done by Electrical Department.

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

Stock verification is carried out on a quarterly basis.

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

Minimum 5 % of new linen checked by SSE/C&W as per guidelines.

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 being ensured. Penalties as applicable are deducted from bill and payment is made after recovery of all penalties / dues.

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

Stock of 2 days washed linen is available in 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

Linen items are condemned as per recommended life of linen or on condition basis.

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

A committee consisting of SSE/C&W/Store, SSE/C&W/Bedroll & Sr.SO/Acounts has been nominated for linen condemnation.

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

Blankets are dry cleaned at two month interval.

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

Passenger complaints are analysed and corrective and preventive action is taken. Complaints on account of dirty & un-cleaned Bedroll have increased to 115 cases during 2011 – 12 as compared to 38 cases in 2010 – 11.

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

Feedback system for quality of linen from coach attendant (CA) is not adequate. CA is not reporting for linen quality in every trip.

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

Pest control is awarded to M/s CWC/Kolkata as per Rly Board’s guidelines. However, performance of pest control agency to carry out pest control is not satisfactory. Complaints on account of pest/rodents have



increased to 92 cases during 2011 – 12 as compared to 10 cases in 2010 – 11.

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

All reserved coaches (both AC and Non AC) are covered for pest control.

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.

The following frequency is adopted for pest control treatment: AC coach – Fortnightly Non AC coach – Fortnightly in first 3 months and thereafter monthly. Pantry car (AC) – Fortnightly. Pantry Car (NAC) – Fortnightly.

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

Pest control management: Fogging is done – CANON

smoke. Rochex, Malathian is used for

pest treatment. Contract has been given to M/s

CWC as per Model condition of contract of Railway Board’s letter no. 200/M(C)/141/7 Vo. IV dated 21.12.10.

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.

Depot is carrying out rodent control treatment as per contract’s provision. However, refuses / left over foods from pantry cars are disposed after arrival of trains in Yard. Refuses of other coaches of train are also disposed in Yard. In addition, all pantry cars are unloaded at platform or in Yard for effective cleaning. Regular rodent control measure is taken inside the depot. However, the following shortcomings noted for rodent control: After dry sweeping of coaches,

all refuses are not collected and some splattered on the pit lines.

Rodent control measure has not been taken by Howrah Division (Engineering/Medical) at HWH platform area.

Complaints on account of rodent have increased to 68 cases during 2011 – 12 as compared to 4 cases during 2010 – 11.

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

Personnel for pest & rodent control are trained.

vii. Fumigation/mist treatment carried out whenever coaches detached for IOH/POH. Pest/rodent control

Pest control is being done in coaches detached for IOH/POH attention. Pest/rodent control is carried out in


SN Item Clause Observation carried out before inducting the coach in service after IOH/POH

off IOH/POH coaches before inducting the coach in service.

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

All reserved coaches (AC and NAC) of a rake are given pest control treatment together.

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


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

Pantry cars are detached from rake once in a month to facilitate complete vacation and intensive cleaning for thorough pest / rodent control treatment

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

As per RB’s guidelines, pest infestation is measured.

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

This is being ensured. Passenger complaints are analysed for corrective and preventive action. Feedback of pest / rodent infestation in coaches through coach attendants or through deployment of Depot official is not taken.

25. Passenger amenities provided in

various types of coaches as

specified.

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

Shop is not providing all amenities in NAC coaches such as snack table, bottle holder and magazine bag. These are found missing in sleeper coaches (NAC).

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

SRC depot has 06 nos standard deep pits. Balance 9 deep pits are non standard design (without Catwalk)

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

Para 1009 of Chg manual

27.1 Wheel and axle Para 1009 a of Chg manual

Attention of wheel sets during 2011 -12: Axle box canted (152 cases), grease oozing (8 cases), warm and hot (nil cases) and other (axle box wing) etc – 64 cases.

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)



SN Item Clause Observation 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:

Supervisors are aware of various wheel defects. However, CMI –K003 guidelines have not been displayed on shop floor and sick line.

a) Shattered Rim This is being ensured.

b) Spread Rim This is being ensured.

c) Shelled Tread This is being ensured.

d) Thermal Cracks This is being ensured.

e) Heat checks This is being ensured.

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 are 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 ensured. En-route detachment of coaches due to roller bearing failure during last 03 years is as under:

Yr LHB ICF TOT

09 – 10

1 - 1

10 – 11

- 3 3

11 – 12

- 7 7

Each case of roller bearing failure is investigated for corrective and preventive action

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

This is being ensured. This is being ensured.


SN Item Clause Observation 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

This is being ensured. This is being ensured. This is being ensured.

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.

This is being ensured. Total 8 wheel sets have been changed in 2011 -12 on account of grease oozing out.

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

Axle box temperature is measured by non contact type temperature measuring instrument during rolling in examination. 4 nos non contact type temperature measuring instrument are available at Howrah PF.

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.


27.4 Minimum permissible wheel diameter in ICH design BG coaches.

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

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

This is being ensured. Shop last issue size in off POH coaches is 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.

This is being ensured. Wheel condemning limit in open line is 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 hanger 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

This is being ensured. There is one hanger breakage case in 2011 – 12.

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

As reported by depot, air brake hoses are not replaced in every alternate POH.

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

RDSO spec and STR This is being ensured.

29.3 FAC amenities are provided as per guidelines circulated vide



SN Item Clause Observation DG/Carrg/RDSO’s letter no. MC/CB/AC/BG dtd 28.04.10

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

Snack table in each bay. 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

As reported by depot, Snack table, magazine holders on partition wall and bottle /tumbler holders are not provided in all sleeper coaches.

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

This is being ensured. 4 Duranto trains are based at SRC depot. LHB coaches have been provided in HWH –CSTM and HWH-Pune Duranto. Hybrid coaches have been provided in HWH-Yeswantpur. Conv ICF EOG coaches have been provided in HWH – Digha Duranto Express.

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.


This is being ensured. Super checking report of officer is not available.

iii) Short distance Duronto with only only AC / Non AC chair car may be permitted to run on the extant pattern for Shatabdi trains with a terminal attention at other end on platform / stabling line. A minimum 2 hrs may be planned at the non primary end to enable thorough attention to cleanliness, hygiene and passenger amenities at other end.


Short distance Duronto (HWH –Digha) is maintained at SRC with RTM.

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

Hybrid coaches (66 coaches) are fitted with air spring. Attention as recommended is given.


SN Item Clause Observation 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.

Primary detachment from coaches are being analysed by depot for taking CA & PA. Major contribution during 2011 -12 is wheel sets due to root wear (26.1 %), axle box canted (10.8%), BP/FP pipe defective (10.8%), axle wing crack (4.5%), tank leaky (6.6%), Main/Lugg/Lav door (3.5%), draw & buffing gear (4.4 %)

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

Record of secondary detachment is not available at depot. Analysis of secondary detachment is not being done.

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.

En-route coach detachment is investigated and necessary corrective and preventive action is taken. Summary of en-route detachment during last three year is as under:

Yr LHB ICF Total

2009 – 10

- 1 1

2010 – 11

1 4 5

2011 – 12

- 9 9

Failure due to hot axle is as under: 2009 -10: 1 case 2010 – 11: 2 cases 2011 – 12: 7 cases.

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.

Status has been indicated in Annexure - I

30 Passenger satisfaction

30.1 OBHS & escorting of trains

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

OBHS through outsourcing as per RB’s guidelines have not been provided. OBHS contract already expired on 31.10.11 and new contract has not been placed by Zonal Railways. Against quotation power, depot is arranging OBHS in Duroanto train ((HWH – Yeswantpur). Depot has planned for OBHS in total 9 important Mail/Express trains.


SN Item Clause Observation ii) Nos of Mail Express train in which

escorting staff have been provided with cleaning staff by depot.

In Duranto trains (HWH – Pune & HWH –CSTM), OBHS is provided by C&W escorting staff.

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

OBHS have been provided in 3 trains (1 through outsourcing and two trains by depot)

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

All major Mail/Express trains have not been provided OBHS through contract and escorting by depot.

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

System exists to verify PSI by depot and deduction has been made accordingly.

30.2 Whether depot has system to get feedback of cleanliness, linen quality and pest infestation of Mail/ Express trains. Action taken by depot on the basis of feedback from passenger.

System to get feedback of cleanliness, linen quality and pest infestation of Mail/Express trains is not adequate. Regular feedback from CA (coach attendant) in standard format is not taken. Feedback of cleanliness, linen quality and pest infestation and OBHS performance through deployment of depot official is not available.

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

Passenger complaints for last three years are as under:

Yr Pest/ rodent

Linen

Others

Total

09 -10

24 48 129 201

10-11

10 38 122 170

11-12

92 115 355 562

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

Depot has awarded contract for mechanised cleaning of 26 PM trains only. Other trains are attended by depot. Cleaning through high pressure jet is done by contractual agency.

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

FAC and composite are provided with upholstery. Carpets have been removed from coaches. Cleaning activity is being carried out through mecahnised cleaning contract.

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

Curtains are cleaned at two months interval.

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

Blankets were cleaned at two months interval..

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

Depot is facing problem due to improper cleaning of coaches by


SN Item Clause Observation maintenance depot particularly in the washing line area.

contractual agency. .

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

Disposal of leftover food and refuses from pantry coaches and other coaches of trains are done after arrival of train at depot. Some refuses also splattered over pit line in the course of maintenance.

c) Sustainable garbage collection and disposal system

Yard cleaning and garbage disposal is carried out through contract. .

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

Drainage is adequate.

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

Periodic pest control treatment is being done through contractual agency. Cleanliness is being ensured in washing area. However, cleaning of coaches by contractual agency is not adequate.

f) Monitoring the functioning of OBHS and CTS scheme.

OBHS through outsourcing as per RB’s guidelines have not been provided. OBHS contract already expired on 31.10.11 and new contract has not been placed by Zonal Railways. Against quotation power, depot is arranging OBHS in Duroanto train ((HWH – Yeswantpur). Depot has planned for OBHS in total 9 important Mail/Express trains.

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.

Officers in SAG have been nominated at Zonal level under “OYTS” by AGM/SER.

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.

Linens are cleaned through mechanised laundry through outsourcing. Laundry as per BOOT model is yet to be provided. Depot has total requirements of approx 10 ,000 packets per day. Extra quantity is normally supplied in each coach.. Regular condemnation is being done on condition / age basis and replenished with new linen.

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

Mechanised laundry has not been sanctioned for SRC depot. Laundry as per BOOT model is to be provided by depot.

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

Packaging and storage is adequate. Servicing to linen is being done by coach attendant of Electrical department

31 LHB coach attention:

31.1 Periodicity of periodic overhauls RB’s letter no. 95 /M (C)/ Depot has total holding of 66 LHB


SN Item Clause Observation (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

141 (LHB) dtd 22.08.06 coaches for Duranto service (HWH –CSTM & HWH –Pune). IOH and POH attentions are given by C&W Workshop, Liluah. Periodic attentions (IOH / POH) as per RB’s guidelines are given. D2 Schedule (Monthly attention) and D3 Schedule (six monthly attentions) are given in rake. For D3 schedule, coach is detached from rake for attention in sick-line.

31.2 Attention to following components are being given as per Alsthom manual guidelines and guidelines circulated by RDSO. Phonic wheel / speed

sensor. Dump valve Earthing device. Control arm Dampers

Primary vertical dampers.

Secondary vertical dampers

Yaw damper. Secondary lateral

damper Primary and secondary

springs Disc brake attention CDTS (Controlled

discharge toilet system)

Alsthom manual and OEM manuals

Contract for disc brake (including air brake) attention in LHB coaches for KB makes and FTIL make brake system has not been awarded Depot is carrying out maintenance attention of KB and FTIL make disc brake system through in-house. Population of KB and FT make disc brake system is as under KB make: 35 FTIL make: : 31 Attention for phonic wheel and speed sensor is given by depot as per recommended frequency. Earthing device is attended through a contract on OEM and all earthing devises are in working condition. Depot is attending CDTS in-house. Spares are procured by depot from OEM. 93% CDTS are in working condition. Depot has received following dampers:

Dampers Recd Used Avail

Primary 65 43 22

Sec vert 38 14 24

Sec lat 43 16 27

Yaw 42 6 36

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

This is being followed. Supervisors are aware of various wheel defects. However, CMI –K003 guidelines have not been displayed on shop floor and sick line.

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

Para 1009 a (i) of chg manual



SN Item Clause Observation 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.

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 is taken for wheel sets with high temperature.

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

Rolling–in examination is being carried out at HWH station. Axle box temperature is measured with non-contact type temperature measuring equipment. Corrective action is taken for wheel sets with high temperature.

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


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

Traceability of wheel sets is ensured. Attention as stipulated is given for attention of CTRB at an interval of 1.2 Million Km. UST attention is given at shop only.

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

Wheel sets with flake is not permitted in service.

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.

This is being ensured. Details have been provided to shop.

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

With existing system, grease oozing out can be checked from front seal only when front cover is opened. This being checked during D2 schedule as front cover is opened for attention. For checking grease oozing out at rear grease seal, bottom control arm to be taken out. Checking of grease oozing out is not done for rear end seal at depot even in D3 schedule.

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



SN Item Clause Observation xii) Checking of mounting bolts of

control arm is being done during primary maintenance.

Mounting bolt is tightened regularly during PM.

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.


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.


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.


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 ensured.

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.

All earthing devices are working. Earthing devices are maintained through AMC on OEM.

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

Earthing devices with connecting wire are available.

Junction box in broken/damaged condition.

Junction box is in good condition.

31.7 Disc brake attention: OEM guidelines

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

Brake pads are renewed on condition basis.

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

Brake callipers of KB and FTILO make are attended by depot as AMC with FTIL and KB is not available.

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

Regular attention is given by depot through in-house. Availability of spares for disc brake system is hampering regular attention of disc brake system.

31.8 Whether guidelines circulated by RDSO for CBC equipped coaches

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

Depot is not aware of Guidelines issued by RDSO. However, at


SN Item Clause Observation are being followed. present coaches sent to and received

from platform with full brake in working to avoid rolling of LHB rake.

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

This is being ensured. Length of buffer is maintained for ASF make and FTIL make as under: FTIL make – 650 mm ASF make – 635 mm


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

SRC depot/SER/KGP is major depot with coach holding of 1419 coaches.

Availability of Machinery and Plant

Description Minor

Depot

Medium

Depot

Major

Depot Observation

U/floor wheel lath - - 1 02 nos available

Whiting jacks (5 Nos.) - 1 set 1 set 18 nos

EOT crane 20T - - 1 25 T carne – 2nos.

Coach Shunter - 1 2 Available under traffic

department.

Welding Plant 1 2 4 18 sets

Gas Cutting Equipment 1 2 2 2 sets

Vacuum Exhauster 1 2 2 Not required.

Air Compressor 30 cfm 1 2 2 6 compressors are

available.

Portable Vacuum Testing

Equipment - 1 1 Not required

Portable Air Compressor - - 1 1 no.

2T Tram beam hoist 1 1 2 1 no

Sewing machine - 1 1 1 no

Truck 10T - - 1 1 no.

Light Coml. Vehicle 1 1 1 1 no.

Fork lift truck - - 1 Not available

Lister truck 1 1 2 02nos

Car Washer - 1 1 Not available.

Portable Trolley Light 2 4 2 nos.

Cotton waste soaking plant 1 1 1 Not required.

Wood cutting saw machine - 1 1 7 nos.


Description Minor

Depot

Medium

Depot

Major

Depot Observation

Hand shearing machine - 1 1 3 nos.

Portable Furnace 1 1 2 1 no.

Centre Lath - - 1 1 no.

Bogie Manipulator - - 1 Not available

Ultrasonic Testing Apparatus 1 1 1 2 nos.

Tool post Grinder - 1 1 1 no.

Vacuum Cleaner 1 2 3 4 nos.

Pressure Jet Cleaner 1 2 4 4 nos.

Tools

a. Pneumatic Hand Tools

i. Grinder 1 1 2 Not available

ii. Drill 1 1 2 Not available

iii. Chipper / Buster - 1 2 Not available

iv. Riveter - - 1 Not available

b. Electric Power Tools

i. Pop Riveting Gun - 1 1 1 no.

ii. Drill - 1 1 3 nos.

iii. Bolt Tightner - - 1 2 nos.

c. Hand Tools As required Available

d. Test Bench

i. Water Tank Test Rig - 1 1 1 no

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

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

iv. Slack Adjuster Test Bench

- 1 1 Not required.

v. DV Test Bench - 1 1 DV testing done at

shop.

vi. Air brake single coach test rig

- 1 1 RTR – 7 nos

SCTR – 4 nos

e. Office Equipment

i. Computer system 1 1 1 Available

ii. Plain Paper Copier 1 1 2 02

iii. Telefax 1 1 Available


Annexure - II

Emergency materials required for platform (C&W) office

SN Items Required Observation

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

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

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

4 Draft link complete 2 sets Available

5 Equalizing Stay rod with pins ( Non-

modif. & Modif.) 1 set each

Available

6 Anchor link with securing studs 1 set Available

7 Truss Bar Hanger with Pins & Cotters 2 sets Available

8 Bolster suspension Link (Stirrup Link)

with Pins & Stones 2 sets

Available

9 Axle Box Face Cover (ICF) with securing

nuts & Pins 2 sets

Available

10 'O' Ring 2 nos. Available

11 Grease Servogen 4 kgs. Available

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

13 Angle cock 2 nos. Available

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

15 M.U. washer 10 nos. Available

16 Teflon Tape 1 no. Available

17 Portable Air Pressure Gauge 1 no. Available

18 Pressure Gauge BP & FP 2 each Available

19 BP & FP Air hose 2 each Available

20 Guard Emergency Application Valve 2 nos. Available

21 Wooden Plug (various sizes) 10 nos. Available

22 Wooden wedge 4 nos. Available

23 G.I. wire Adequ. Qt. Available

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

25 Push cock 5 nos. Available

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

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

28 Hydraulic Jacks 2 sets Available


Annexure – III

Details regarding coaching depot

Depot name and division: SRC / SER / KGP Division

1. Coach Holding

Mail/Expresses coaches with conventional coupling 1098

Mail/Expresses coaches with CBC coupling (ICF

design)

171

Hybrid coaches 66

LHB coaches 66

Rajdhani/Shatabdi coaches (conv) 18

Grand Total 1419

2. Maintenance attention of at depot

Mail Express trains



RT attention 15


Intercity trains


4

Total attention 64

3. Pit line attention

24 coach pit with catwalk and high pressure

water jet facility/watering facility at per

CAMTECH’s guidelines

6 CAMTECH design deep pits without

high press jet facility. Portable jet

machines are used.

24 coach pit facility with catwalk and

washing apron

01 no.

Less than 24 coach pit facility with catwalk

and washing apron

08 nos

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

03 nos

03 nos.

Compressed air with reservoir and air

dryer/moisture trap facility with test rig (RTR)

6 nos compressors (200 CFM – 2 nos,

350 CFM – 2 nos, 360 CFM – 1no.,

325 CFM – 1 no.) are available with air

dryer facility.

Facility for welding at Yard attention Facility for welding at Yard attention is

available.


Night maintenance facility with overhead/pit

light as per CAMTECH’s guidelines

Deep pit lights are not working. Tube

Lights are provided under catwalk.

Minor lamps are used for pit attention.

Lights have been provided over poles.

Overhead lights have been provided

for general illumination. Night

maintenance facility is available in 04

pits at SRC

Sick line facility:

Coach lifting facility with overhead crane 8

Coach lifting facility with JMP jack/hydraulic

jack

6 nos.

Total coach accommodation

With pit attention Without pit attention

10 coach

4 coach

Facility for compressed air with test rig

(SCTR)

04 nos.

Availability of hydrant water for overhead

tank attention

Water hydrant is available.

Welding facility Available

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

arrangement (for attention during night) as per CAMTECH’s guidelines:

Lighting arrangement for rolling–in examination is available except for PF-17, PF -

21 & PF-23) at HWH station. ARM/SRC has requested DRM/HWH for arranging

lighting arrangement and one room for keeping tool boxes of TXRs..

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

Availability of manpower vis-à-vis requirement as per yard stick (bench

marking norm) is as under:

Activity

Requirement as per

Yard stick (bens

marking norm)

Availability Shortfall

/Excess

For cleaning activity 784 174 -610

For under-gear

attention

904 792 -112

For sick-line activity 204 90 -114

For ancillary work 235 111 -124


For cleaning activity, shortfall has been compensated through contact (566

man-powers engaged)

7. Training status of supervisor and staff –

Monitoring of Due / overdue training for supervisors / Artisan is not adequate.

8. Availability of critical/ safety stores and storage system: Safety list has been

published by RB. Depot is yet to reconcile safety store as per RB’s guidelines.

Stock of safety items as per present list is available. Stacking is not adequate.

Store is congested and items have not been labelled.

9. Availability of coaches as per rake link with maintenance spare: Against

requirement of 1200 coaches, total available stock is 1419. (Maintenance spare

as per yard stick is available).

10. Bottlenecks / limitations of system / depot:

Lack of direct admission facility at WCD: There is lack of direct reception in

washing cum departure Yard due to which all trains are being received at

reception yard and from there placed at NCG & WCD which necessitate

multiple shunting movement.

Lack of dispatch and reception facility from Reception – Yard to Shalimar.

Only 2 out of 9 lines in R- yard is designed for long composition (23/24

coaches). Threr is only one shunting neck to handle the rakes. The yard is not

provided with catwalks and is having overhead wires which require multiple

placements for exterior cleaning.

Total 21 trains are to be dispatched from 15 to 23 hrs. while in washing –cum

departure yard, threr are only 03 lines of 24 coach capacity. Not more than 2

rakes can be tackled in WCD for attaching and detaching of coaches.

Stabling facility is available for 123 coaches while requirement is for 160

coaches.

11. Safety performance record:

There is no derailment / accident on C&W account.

There is 9 en-route detachment of coaches in 2011 -12 out of which 07 cases

are due to roller bearing failure..

12. Performance of critical spare:

Depot has not highlighted any issues of critical spare.

Documents

Quality Audit report Of Coaching Depot Santragachi, SE Rly