Workshop Facilities for a Metro [Compatibility Mode]

8/2/2019 Workshop Facilities for a Metro [Compatibility Mode]

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Vikas Sardana – DGM – O&M um a e ro

07th

Feb, 2012



Introduction

ROLLING STOCK is The Backbone of any Urban

transport system Lower Downtime is need of hour

Innovative and quick maintenance practices being

Depot facilities to match to the requirement of faster

and safer maintenance



Typical Depot Facilities

. o. ac ty emar s

1.0

1.1 Workshop Heavy Maintenance

1.2 Inspection Bays Lig t Maintenance

1.3 Stabling lines

Parking

and

Daily Checks

/ Cleaning

1.4 Automatic plant Run through cleaning

1.5 Blow Down Plant

.

vehicles

1.7 Underfloor wheel lathe Wheel re‐profiling

1.8 Heavy cleaning

line For

external

heavy

and

roof

washing

2.0 Other Facilities2.1 Workshop for overhauling of trains Maintenance Labs and Shops

2.2 OCC DCC and trainin school buildin Driver trainin simulator shall be installed

in OCC

building

2.3 Administration building Offices

2.4 Store Centralized store common to all functions

2.5 Rerailing equipment stabling Separate garage near Workshop

2.6 Water treatment plant For treatment of raw water

2.7 Eff luent treatment

and

sewage

treatment

plant For

treatment

of

drain

water



Metro Maintenance Practice

Preventive Maintenance

Daily Checks

A checks

C Checks(IOH)

er o c over au s

Unscheduled Maintenance



Metro Maintenance Facilities

Light Maintenance

Inspection Bays

Heavy Maintenance

Dedicated Cleaning Bays

ers – as an , ee a e e c.



Metro Light Maintenance Facilities

Light Maintenance

Inspection Bays: 3 tier maintenance set‐up




Light Maintenance

Inspection Bays: 3 tier maintenance set‐up

Once a

week

– under

frame

inspection

,




Light Maintenance

Inspection Bays: Typical maintenance equipment




Light Maintenance

Inspection Bays: Under slung Crane: For Roof Mounted Equipment




Light Maintenance

Inspection Bays: Mobile Lift Table: For Underframe Equipment




Light Maintenance

Inspection Bays: Other facilities

Compressed Air

Supply

– 10

bar,

available

within

20

m

– ,

Wheel profile gauge – Check tread and flange wear

equa e g ng or un er rame nspec ons




Light Maintenance

Inspection Bays: Key Activities

Cleaning,

Visual inspection, , Measurement of various parameters,

Condition base

Replacement

, Realignment,

es ng o var ous equ pmen s, Function test , Safety independent check,

Modification or

special

cyclic

check

&

attention,




Place the train in Inspection Bay

g t

a ntenance

Inspection Bays: Typical ChecksIsolate OCS Supply and inspect the

roof

Download TCMS Data

Analyze TCMS Data,

Any failurerecorded/ observed?

Rectify the failure

Any failurerecorded/ observed?

Yes

Yes

No

Clean Panto and other roof mountedequipments

Visual Inspection, Measurements,Tests, Filter replacement

Any failureobserved?

Rectify the failure

Yes

Clear the roof and charge the OCS,Make the train Power ON

Perform the function tests and test

stipulated in check sheet

Any failurerecorded?

Rectify the failure

Train ready for Service

Yes



Metro Heavy Maintenance Facilities

Heavy Maintenance: Workshops





eavy

a ntenance

Workshop: Activities: Bogie Removal



eavy

a ntenance

Workshop Equipment – Bogie Removal



eavy

a ntenance

Workshop Equipment: EOT Cranes

EOT Cranes are required

or t e materia i ting in t e

Workshops

Workshop requires an

extensive lifting and

movement of

qu pment mater a

ur ng

the maintenance of Rolling

Stock, especially during the

.



eavy

a ntenance

Workshop Equipment: Mobile Jacks

Mobile jacks

are

required

to

lift

the train/locomotive or any other

.

Mobile

jacks

offer

a

great

deal

of

any place and vehicle of type can

be lifted.

Mobile jacks

work

in

mutual

synchronization,



eavy

a ntenance

Workshop Equipment: Bogie Turntables

Bogie turn table is used to rotate

the Bo ies and to transfer the

Bogies from one track to the other.

Bo ie turn

tables

hel s

expediting the maintenance

process.



eavy

a ntenance

Workshop Equipment: Re‐railing Equipment

Re‐railing Equipment are required to

put the de‐railed vehicle back on the

rac s.

Re‐railing Equipment contains the

specialized light

‐ weight

lifting

jacks

and

hydraulic power packs etc. for lifting the

derailed vehicle.

‐ ‐

container on

which

these

equipment

can

be carried to the rescue site through rail or through road.



eavy

a ntenance

Workshop Equipment: Bogie Test Bench

Bogie is one of the most criticals stem of Rollin Stock.

Bogie test bench is necessary tocheck the characteristics of rimarsuspensions and wheel loading afterthe maintenance of Bogies.

Bogies are tested on the bogie testbench to confirm whether the various limits are within tolerance

into service.



eavy

a ntenance

Workshop Equipment: Electric Tractor

Electric tractor is a small road‐cum‐rail vehicle to move

the train within the workshop

area.

Electric tractor is a battery driven vehicle.

ra n movemen s w

Electric tractor are limited only to the Depot.



Metro Maintenance Facilities

Wash Plant

Run through washing

Sides, Eaves

and

end

washing

. The

complete train washing takes about

3‐10 m nu es epen ng upon areas

selected to be cleaned.

‐

system to minimize the usage of water.

Fresh water

is

processed

to

get

RO water especially for the window

glass cleaning, which if cleaned with

norma water s a reta n w te stains.



Wheel Lathe

Specialized CNC machine for turning the

Wheels of Rolling Stock and locomotive to getthe proper wheel profile, without removing

.

Wheel lathe automatically measures and

wheel to achieve the correct wheel profile.



Wheel Lathe

Wheel rofile: RDSO Dr SK 11

UIC, EN.

Machining of inside faces of wheel

Chip crusher & Conveyer belt (scrap

collection). Extraction of smoke by a vacuum

pump.

Remote train operation 200 mtrs Remote fault diagnosis by OEM

apa e o mac n ng ra e s n

disk braked RS.



Bogie Wash Plant

as ng, ra n ng, r ns ng,

draining, vapour evacuation. First phase: washing with spray of

detergent mixed water heated to80°C maximum, then draining

Second phase: rinsing with spray of plain water heated to at least 50°C,then draining.

Third hase: Exhaust blower

operation, drawing steam from thechamber and discharge it toatmos here



Wheel Press



Other Equipment: Material HandlingS.No Equipment Purpose Location

1 Electric Fork Lift ‐ tonnes ca acit For carr in the heav e ui ment Worksho and Store

2 Pallet

trucks‐

2

tonnes

capacity For

carrying

heavy

equipment Workshop

and

Store

3 Mobile lifting table For removal of equipment fitted on

the under frames, shall be located

On outer inspection lines

in the Inspection bays

4 Work lift platform operated, Mobile Scissor Lift

Mobile table to work on heights

5 Mobile platform Mobile platform with stairs to

access the Cab in Inspection Bay etc

6 Electric Stackers – 1.5 tonnes, 5 m range For carrying heavy Equipment Workshop and Store

7 Saloon access platform To board the train in Inspection

bay/workshop

Workshop/

8 Mobile Jib Crane‐1 tonnes To lift the material Also required for pit wheel lathe to lift

spare/calibration wheel set

9 Scissor lift table – 5 tonnes, To work on sides of train (to

change glass/door leaf etc)



Documents

Workshop Facilities for a Metro [Compatibility Mode]