Dra ft R eport on Infrastructural Facilities Required in ... Report on...

IRCAMTECH/MECH/GWL/INFRA/LHB/WS 1

Report on Infrastructural facilities for Maintenance of LHB Coaches in Workshops

Government of India Ministry of Railways

Draft Report

on Infrastructural Facilities Required in

Workshops for Maintenance of LHB Coaches

CAMTECH/2015/M/LHB-INFRA/1.0

July – 2015

(For official use only)



Draft Report

on

Infrastructural Facilities Required

in Workshops

for

Maintenance of LHB Coaches



Preface Railway Board has issued instructions vide letter No. 2007/MC/141/1 dated 12.03.14 to CAMTECH to prepare Report on facilities required in workshops to streamline LHB coach schedules to minimise maintenance cost etc. During meeting for “Review of IOH/ POH periodicity of coaches and performance review of LHB coaches” held in Railway Board on 06.03.2014, it is also decided that Report should be prepared according to requirement in line with DMRC and revision in M&Ps should also be done to have full complement of tools/equipments & other machine plants.

This Report is prepared with the objective to provide informative technical details on Infrastructure for LHB Coach maintenance for the guidance of Mechanical engineers involved in maintenance of LHB Coaching stock in workshops. It covers the constructional features of maintenance Bays, lay out drawing of pit line, Various maintenance sections, M&Ps required, Tools and equipments, flooring, EOT cranes & type of sheds and its length etc. This Report does not supersede any existing instructions from Railway Board, RDSO & Zonal Railways and the provisions of Maintenance Manual for LHB coaches. This Report is not statutory and contents are only for the purpose of guidance. Most of the data & information mentioned herein are available in DMRC and Workshops on IR.

We welcome any suggestions from our readers for further improvement.

CAMTECH/Gwalior (K.P.Yadav) Date : 20.07.2015 Director/Mech.



ABBREVIATIONS

ABS Air Brake Shop

BC Bogie clearances BCS Bogie Component Shop BAS Battery Shop BHA Buffer Height Adjustment BRS Bogie Repair Section CCS COACH CLEANING SHOP CRS COACH REPAIR SHOP CoC Coach over Coach CPS Carpentry Section CBRS Coach Body Repair Section CT Cycle Time CPDOT Coach Per Day Out Turn ICS IN COMOING SHOP IGP Indo-German Project JICA Japan International Cooperation Agency LSB Lower Spring Beam OGS OUT GOING SHOP PAS PAINT SHOP PL Parel Work shop, WR PER Perambur Work shop, SR POH Periodic Overhaul PWT Plumbing and Water Tank Section CTRBS CTRB/CTBU Section RCF Rail Coach Factory RRV Rail Road Vehicle CBCS CBC and Draft Section T Traverser TLS Train Lighting Section TRS Trimming Section WAS Wheel and Axle Section



I N D E X

S.No. Description Annexure Page i Preface -- 3 Ii Abbreviations -- 4 iii Index -- 5 iv Correction Slips -- 6 1.0 Introduction -- 7

1.1 Need for LHB Coaching Infrastructure -- 7 1.2 Major/Prominent factors necessitating change in Coaching

Infrastructure in Workshops -- 7

2.0 Objectives -- 8 2.1 Maintenance stages -- 8

3.0 Terms and References -- 9 4.0 Zeroing in Essential Requirements -- 9 5.0 Various Essential Requirements -- 9 6.0 Evolving Maintenance Philosophy & Concept -- 10 7.0 Various Work Centres and POH Activities -- 14 8.0 Various defining principles/concepts for developing ideal

maintenance facilities for green field projects -- 16

9.0 Salient Features of infrastructure -- 18 A List of important M&P required in respective shops Annex-I 20 B Berthing Capacity of various work centres Annex-II 24 C Details of Infrastructure facilities proposed for POH workshop for

200 LHB coaches Annex-III 25

D A View of Pit line at DMRC on Steel pillars Annex-IV 28 E Scrap Disposal system Annex-V 29 F Automatic In-motion Train Washing System(ACWP) Annex-VI 30 G Internal Coach cleaning machine Annex-VII 39 H Flooring in the workshop Annex-VIII 40 I Illumination level Annex-IX 42 J Roofing in Workshop Annex-X 43 K Air Ventilation System Annex-XI 46 L Details of EOT Cranes Annex-XII 47 M Coach over coach system in maintenance Bays Annex-XIII 48 N Transportation Codes for LHB Coaches Annex-XIV 49 O Shop wise Summary of Parameters Annex-XV 50 P Suggestions given by Zonal Railways during Seminar 51 Q Model Lay out for 5 Coaches daily out turn Annex- 52 R CCS – Coach Cleaning Shop with ACWC Annex- 53 S ICS- Incoming Shop, Trimming, plumbing, water tank, ABS Annex- 54 T CRS- Coach Repair Shop, BRS, BCS, CPS Annex- 59 U PAS- Painting Shop Annex- 62 V OGS- Out going shop Annex- 63 W ACS- AC Shop, TLS, BAS Annex- 64



ISSUE OF CORRECTION SLIPS

The correction slips to be issued in future for this handbook will be numbered as follows: IRCAMTECH/MECH/GWL/INFRA/LHB/WS/1.0/CS. # XX date . ..…………..... Where “XX” is the serial number of the concerned correction slip (starting from 01 onwards). CORRECTION SLIPS ISSUED

Sr. No. of C.Slip

Date of issue

Page no. and Item No. modified

Remarks



1.0 INTRODUCTION:

In Indian Railways, traffic is consistently increasing due to largest mode of transportation in this country. To cater this increased traffic need, high capacity LHB coaches were introduced by Railways and population of theses coaches is also increasing day by day. For carrying out POH/IOH schedule in the workshop for meeting requirement of traffic, it is felt necessary to strengthen the workshop activities for timely maintenance. The modernized workshops should have optimal integrated working i.e. suitable lay out, modern material handling and storage facilities, work stations and other related infrastructures. 1.1 Need for LHB Coaching Infrastructure

LHB type coaches are running in prestigious trains on IR. Initially, imported coaches were inducted in New Delhi-Lucknow Shatabdi train and further introduced in Mumbai-Delhi Rajdhani & Delhi-Howrah Rajdhani Express trains with indigenously built LHB coaches. A large no. of technological changes have been made in the past 10 years in these LHB coaches for better and safe service. Moreover, superior design features and materials have been used in these coaches.

Some design changes/technological developments/superior materials definitely helping in enhancing the quality and life of component of LHB coaches but streamlining of maintenance facilities in the workshop is also a factor of consideration.

Type of coaches Periodicity for IOH Periodicity for POH AC/Non AC LHB 18 months 36 months

The upgrading of rolling stock quality and improvement in productivity is very important not only for workshop modernization but also for the Railways as a whole from the point of effective use of rolling stock and improving the transportation quality, thereby devising infrastructural facilities is necessary.

1.2 Major/prominent factors necessitating change in coaching infra in workshops

are summarized as under: -

• Availability of proven new concept like CoC system in shops • Introduction of PU paint technology

• Introduction of more & more AC/Non AC LHB coaches. In line with the measures for improving the passenger service through the increase in coaches, the need for inspection & repair techniques for these coaches and the consolidation of corresponding equipment and facilities in the infrastructure have become a pressing requirement.

All these changes call for a change in the facilities (process flow, lay out, M&P

and infrastructure for POH workshops).



2.0 OBJECTIVE The objective is to develop a maintenance infrastructure for LHB coaching workshop with a view to standardize the infrastructure and systems so as to have a high level of productivity and quality in the various shops.

2.1 Maintenance Stages

Infrastructural facilities for coaching workshops, comprising of layout, Maintenance bays, M & P, material handling equipments would largely depend on POH process & desired cycle time. Therefore it becomes imperative to define POH process clearly & fix maintenance cycle time of repair at each stage.

There are 6 main stages for carrying out POH activities of a LHB coach. These are:

A. Exterior Cleaning of entire coach B. Incoming Coach section: Inspection and stripping etc. C. Coach Repair Section: Complete repair of Body and Bogie & corrosion

repair. D. Paint Shop: PU Painting of body in SS3 E. Out Going Shop: CBC & Buffer Height Adjustment and Clearances, air

brake and electrical testing, inspection by NTXR and Customer. F. AC Coach Repair: Attention to all AC Elect. Repairs & attention to all

Running gears.

For carrying out repair at these 6 stages, we basically need 6 major work stations. These 6 main work centers are:

• Coach cleaning shop - CCS • In-coming shop - ICS • Coach Repair shop - CRS • Paint shop - PAS • Out-going shop - OGS • AC Maintenance Shop - AC Shop

No of days coach would remain at these work centers under existing system of POH are:

• CCS - Nil • ICS - 04 • CRS - 12 • PAS - Nil as it is a parallel activity in CRS • OGS - 02 • Total - 18 days



3.0 TERMS AND REFERENCES

For comprehensively addressing the issues, following have been studied.

i) Stage/working systems at Lower Parel Workshop.

ii) Revised scheme of working of Gorakhpur workshop/NER.

iii) The Indo German Project report for Lower Parel workshop/WR and Matunga workshop/CR and the corresponding advancements incorporated in the workshops as a result of the project.

iv) Stage/Modular working systems at CRWS/Bhopal.

4.0 Zeroing in essential requirement.

With the advent of PU paint technology, the requirement of Paint booth/ oven has become "must" in the paint shop. As such, the Painting work station needs to be designed suitably . The very presence of a traverser between Paint booth and oven would ensure high productivity. A single colour scheme for LHB coaches would further enhance the productivity of Painting work stations.

5.0 VARIOUS ESSENTIAL REQUIREMENTS –

After careful study of coach process flow given in the Maintenance Manual and study of various process flow and lay outs of various workshops and visit to various workshops, it has been concluded that following are the essential requirements for developing any coaching facilities for workshops.

a) Coach over coach concept in Coach Repair Shop (CRS).

b) Traverser in Paint shop because of multiple movements of coaches in and out of Paint booth & oven and a lot of manual work like masking/de-masking/wet rub down, screen printing, putty application and drying in air etc.

c) Shifting Trimming section nearer to CRS.

d) Separate AC shop because of higher cycle time due to specialized activities. e) Separate HCRS (Heavy Corrosion Repair shop) because of varying and excessive

cycle time of repair. The car body is subjected to considerable strain during corrosion treatment because this work is carried out by cutting and welding the body panels and the various structural members. The buried surface plate may be provided in the floor surface of this area to eliminate this strain on coach body.

f) Track in SMS (Sheet Metal shop) and WAS (Wheel and Axle shop) for loading and

unloading of wagons.



g) Bogie transfer arrangement between CRS (Coach Repair shop) and BRS (Bogie Repair shop).

h) Two wide road parallel to track connecting ICS and OGS for transporting Electrical

items such as batteries, fan, tube light, regulator etc. & to provide adequate space for Pusher to maneuver & push the coaches to next stage of POH cycle.

i) Air Brake Section having pipe repair, overhauling of DV, Brake discs & air reservoir

and other parts nearer to CRS. Unit exchange of brake items and maintenance of associated piping in BRS.

j) Jacks in for CBC/Buffer Height Adjustment and maintaining bogie clearances. 6.0 EVOLVING MAINTENANCE PHILOSOPHY & CONCEPT

Following maintenance concepts and principles have been utilized to develop coaching Infra facilities in workshops:

• Uniflow This should not only to be ensured for complete coach but also for sub-assemblies & components.

• Unit exchange Unit exchange of sub assemblies/components (RMPU, DV, brake items/Brake disc, bogie, buffers, CBC/Draft would enable drastic reduction of detention to coach undergoing POH.

• Provide rather than produce Earlier when industries were not developed, there was a need to have in-house production, so having smithy shop, machine shop, tool room was the necessity. Now, with the plenty of industries around and cheap production, these shops need not be planned in any coaching workshops. The man power thus saved could be utilized to step up the out turn which is the need of the hour.

• Replace rather than in-situ repair Adequate number of sub-assemblies & components are to be arranged, so that these are utilized as unit exchange with that of repairable components and coach is moved forward to next stage of repair in the belt system of POH repair. This would reduce the repair time substantially at each stage of POH.

• Separate clean & dirty area Outsourcing of all the cleaning activities (shot blasting of exterior portion of coach body, shot blasting of bogie components, springs, shop floor sweeping etc) is desirable. However, wherever (like CTRB room) it is not possible to outsource, cleaning machine is to be installed and it is to be ensured that dirty/clean area are physically separated.



• Least movement of men & material Support shops are to be laid adjacent to main work centers for faster movement of men & material for improved productivity.

• Outsourcing non core activities & un-economic activities Any activity which can be outsourced should be outsourced, so that more number of coaches can be POHed with the available man power. This is the need of hour, as population of coaches increasing leaps & bounds. Areas of outsourcing are:

• Full CBC Unit • Entire cleaning activities & CTRB Maintenance by OEM

only. • AMC of air brake system of all type of LHB coaches • AMC of CDTS/Bio toilets. • PU painting as operation of paint booth can be given to

supplier to make it a success. Even before paint booth is installed, it can be outsourced.

• RMPU repair • repair of fan, compressor, evaporator alternator etc. • Berths

• Maintenance of sub-assemblies by OEM With the advance technology (like CDTS, WSP, CTRB etc) creeping in, it is desirable to go for AMC with the OEM to reap the advantages quickly to keep down time of coaching stock bare minimum.

• Effective supervision cum space utilization Area between columns of two adjoining bays of sheds is the most appropriate place for making supervisor’s cabin on the stilt & utilizing ground floor portion for storing worker’s tools or storing materials.

• Dedicated ergonomically designed work stations having Powered tools/balancer etc Near the work station, there should be adequate number of powered tools including battery operated and balancers to reduce fatigue of workers.

• Dedicated ergonomically designed work stations having Provision of utilities Utilities like acetylene, oxygen, CO2, electricity, air, water need to be provided to improve man power productivity.

• Standard patches of SS sheet Sufficient numbers of SS sheet patches/panels are to be procured for ready to be used for repair of interior paneling.

While this proposed template in its entirety could be very useful for green field project, the various concepts/ principles utilised in evolving this template, may be used in brown field projects also, using this report as ready reckoner



Using above concepts & principles, Maintenance philosophy is now, centered around the concept of work flow which would ensure movement of coach/bogie/wheel/other components in one direction. Work flow would ensure a continuous work process (work chain or even "assembly like operation". This would not only ensure optimum use of infrastructure but also improved quality of repair. All out efforts are to be made to avoid bottle-necks which may otherwise lead to collapse of work flow. The process planning for Coaching infrastructure optimizes the repair cycle. The center-piece of the workshop is a high height shed, with "coach over coach" transfer facility, where the coach remains stationary for a major part of its repair cycle time (3 days). Different parts, components and sub assemblies are taken out, moved to repair sections and repaired or new parts are fitted back on the coach. Meanwhile corrosion and other repairs on the body and under frame are carried out in situ in the lifted condition of the coach on trestle. The coach over coach concept allows full flexibility in placement and removal of all kind of coaches either slow or fast moving corrosion repair coaches. The philosophy visualized and adopted in the process planning of coaching template is that the support repair shops are situated nearby to main work stations. The Bogie, Wheel and Roller Bearing shops have been laid out adjacent to CRS in a scientific manner. Sufficient time and attention has been allowed on repair of these vital components, which have a direct bearing on the safety as well as in service availability of the coach. Another important feature of the infrastructural facility is to position traverser between paint booth & oven for ensuring faster multiple movement of coach during entire painting process. This traverser also serves ACS, thereby making workshop layout very compact.

The coach for POH repairs is placed on the incoming line by a shunting loco of the workshop. It picks up 5 coaches from the adjacent workshop yard reception lines & places these coaches at washing apron of Coach cleaning work station for external washing. The purpose is to remove all muck & dust here itself so that repair area inside workshop remains neat & clean. After cleaning coaches are pushed to next shop ICS for next stage of POH. After initial examination and stripping (Train Lighting items and Trimming items) at ICS, the coach is placed in CRS by pusher (as shown in Annexure). Coach bodies are lifted and lowered on the trestles. Complete repairs are carried out on trestles in CRS. Bogies removed from the coach are moved to Bogie Repair shop. Repaired bogies are brought back to lifting & lowering area of CRS. The repaired coach is lowered on the bogies and moved to Paint shop for painting. Subsequent to painting the coach is placed in the out-going shop i.e. OGS by pusher for fitment of Train Lighting items including batteries, electrical testing & air brake testing, BHA & maintaining bogie clearances and final examination by NTXR/Customer. The coach after POH is moved to dispatch lines of the adjacent yard by the shunting locomotive



of the workshop. The rake of off-POH coaches from the workshop yard is taken out for onward dispatch to the various divisions of the Railway. Thus the five main stages, which a coach would undergo during POH in the workshop, can be summarized as under – Stages of POH Location of stages Activities performed 1st Coach Cleaning shop Exterior cleaning of coach

2nd

In Coming shop Stripping of Trimming and Train Lighting items, testing of water tank

3rd Coach Repair shop Complete repairs of coach 4th Paint shop Painting of coach

5th

Out going shop

Fitment of Train Lighting items including batteries & testing, Air brake testing, CBC height adjustment & Brake disc, examination by NTXR & DCWI & dispatch.

In order to shorten the cycle time as much as possible, coaches should flow smoothly and waiting time should be minimized. For this purpose, heavy corrosion repair coaches and AC coaches whose cycle time varies greatly, are moved to separate locations, thereby allowing normal POH coaches, which are about 80%, move smoothly on the belt system. The identified heavy corrosion coaches are moved to separate HCRS by pusher for repair. Coach body is lifted & kept on the trestle using coach over coach concept. After repair, it is brought back to CRS for further repair and then moves on "belt" system of POH repair. AC coaches having special requirement are sent to AC shop by traverser. The Paint shop is designed with an automated paint booth, drying oven and a traverser between them and areas for surface preparation and stenciling with hydraulic platforms in order to improve the productivity and quality and life of painting.

The store wards are to be de-centralized and located adjacent to the consuming shops. While purchase order is to be placed for the entire year’s requirement, it should be ensured that the staggered supply i.e. monthly or quarterly material is supplied in order to reduce space requirement Standardized, modular storage arrangements are to be designed for packaged and palletized handling by material handling equipments. Scrap and released materials will be dumped into trailers in the shops. Segregated scrap in the trailers will then be moved by tractor to nominated scrap dumps on daily basis. An incinerator and a liquid effluent treatment plant are to be provided for there disposal. With the advent of PU paint technology which necessitates the use of paint booth and drying booth, it is possible to do this work in 1 to 2 days by introducing a traverser between painting booth and drying oven, therefore it is desirable to delink this activity with body repair.



7. VARIOUS WORK CENTRES AND POH ACTIVITIES

WWoorr kk CCeennttrr ee

SShhoopp

NNaattuurr ee ooff AAcctt iivvii tt iieess

CCyyccllee tt iimmee//

DDuurr aatt iioonn

CCuumm.. DDuurr aatt iioo

nn

SShhooppss iinnvvoollvveedd

11 22 33 44 55 66

AA CCCCSS EExxtteerriioorr cclleeaanniinngg ooff ccooaacchh 00..55 00..55 CCCCSS

BB II CCSS PPrree SSuurrvveeyy && IInnssppeeccttiioonn 11..55 22 IInnssppeeccttiioonn

SSttrriippppiinngg && uunnllooaaddiinngg aall ll eelleeccttrriiccaall ii tteemmss ll iikkee ffaann,, LLiigghhttss,, bbaatttteerryy eettcc.. aanndd ttrraannssppoorrttaattiioonn ttoo TTLL sshhoopp..

TTLL sshhoopp

SSttrriippppiinngg aanndd rreemmoovvaall ooff BBeerrtthhss//uupphhoollsstteerriieess.. TTrriimmmmiinngg sshhoopp

RReemmoovvaall ooff CCeennttrree PPiivvoott ,, ootthheerr rreellaatteedd ii tteemmss BBooggiiee RReeppaaiirr sshhoopp

TTeessttiinngg ooff wwaatteerr ssyysstteemm iinncclluuddiinngg wwaatteerr ttaannkk && ddiissmmoouunnttiinngg ooff BBiioo--TTooii lleett ttaannkk

WWaatteerr ttaannkk sseeccttiioonn

PPuusshhiinngg ooff ccooaacchh ttoo CCRR sshhoopp bbyy PPuusshheerrss CCRR sshhoopp

CC CCRRSS ((8800%% ))

LLii ffttiinngg aanndd ppllaacceemmeenntt ooff ccooaacchheess oonn ttrreessttlleess 33 55 BBooggiiee rreeppaaiirr sshhoopp

SSttrriippppiinngg,, tteessttiinngg,, rreeppaaiirrss aanndd rreeff ii ttttiinngg ooff CCBBCC ccoouuppll iinnggss && BBuuffffeerrss

CCBBCC sshhoopp

UUnnddeerr ffrraammee ssccrraappppiinngg aanndd ppaaiinnttiinngg PPaaiinntt sshhoopp

TTrraannssffeerr ooff BBooggiieess ttoo BBooggiiee rreeppaaiirr sshhoopp uussiinngg ttuurrnn ttaabbllee//EEOOTT ccrraannee aanndd BBooggiiee cclleeaanniinngg..

BBooggiiee RReeppaaiirr sshhoopp

AAtttteennttiioonn ttoo ttuubbuullaarr sseeccttiioonn//TTrroouugghh ff lloooorr eettcc.. CCRR sshhoopp

IInnssppeeccttiioonn && ddiissmmaannttll iinngg ooff AAiirr BBrraakkee ccoommppoonneennttss.. AAiirr BBrraakkee

AAiirr BBrraakkee aasssseemmbbllyy wwoorrkk AAiirr bbrraakkee

AAll ll IInntteerriioorr ccaarrppeennttrryy wwoorrkkss CCaarrppeennttrryy sshhoopp

AAtttteennttiioonn ttoo ttooii lleettss,, wwaatteerr ppiippee ll iinnee,, ccoommmmooddee cchhuuttee,, wwaasshh bbaassiinn eettcc..,, TTeessttiinngg,, rreemmoovvaall ,, rreeppaaiirr//rreeppllaacceemmeenntt && ff ii ttmmeenntt ooff wwaatteerr ttaannkkss..

PPlluummbbiinngg && WWaatteerr ttaannkk sshhoopp

LLiigghhtt bbooddyy ccoorrrroossiioonn rreeppaaiirr wwoorrkk,, AAtttteennttiioonn ooff BBaatttteerryy bbooxx,, MMaaiinn ddoooorr,, ddoooorr wwaayyss,, FFoooott sstteepp,, VVeessttiibbuullee,, sshhuutttteerrss

CCRR sshhoopp

LLaayyiinngg ooff FFlloooorriinngg,, LLooaaddiinngg aanndd ff ii ttmmeenntt ooff uupphhoollsstteerriieess

TTrriimmmmiinngg sshhoopp

DDiissmmaannttll iinngg && rree--aasssseemmbbll iinngg//rreeppllaacciinngg ooff BBooggiiee ccoommppoonneennttss,, wwhheeeellss,, AAiirr bbrraakkee ii tteemmss eettcc ffrroomm tthhee BBooggiiee..

BBooggiiee CCoommppoonneenntt sshhoopp

SShhoott bbllaassttiinngg ooff BBooggiiee BBooggiiee rreeppaaiirr sshhoopp

IInnssppeeccttiioonn,, ddiissmmoouunnttiinngg ooff bbeeaarriinnggss,, rreeppllaacceemmeenntt ooff bbeeaarriinnggss ((wwhheerreevveerr rreeqquuiirreedd)).. TTrraannssffeerr ooff wwhheeeellss ttoo WWAASS

CCTTRRBB sshhoopp..

IInnssppeeccttiioonn,, ttuurrnniinngg ooff wwhheeeellss//rreeppllaacceemmeenntt ooff AAxxlleess,, ddiissccss,, pprreessssiinngg ooff wwhheeeellss eettcc..

WWhheeeell sshhoopp

LLoowweerriinngg ooff CCooaacchheess oonn BBooggiiee BBooggiiee sshhoopp

TTrraannssffeerr ooff ccooaacchh ttoo PPaaiinntt sshhoopp bbyy TTrraaccttoorrss CCRR sshhoopp



WWoorr kk CCeennttrr ee

SShhoopp NNaattuurr ee ooff AAcctt iivvii tt iieess CCyyccllee tt iimmee// DDuurr aatt iioonn

CCuumm.. DDuurr aatt iioo

nn

SShhooppss iinnvvoollvveedd

HHCCRRSS ((2200%% ))

CCooaacchheess rreeqquuiirriinngg hheeaavvyy ccoorrrroossiioonn rreeppaaiirr wwii ll ll bbee bbrroouugghhtt ttoo HHCCRRSS oonn dduummmmyy ttrrooll lleeyy ffrroomm CCRR sshhoopp.. TTrraannssffeerr bbyy ttrraaccttoorr aanndd tthheenn tthhrroouugghh ttrraavveerrsseerr

1100 1155 HHCCRRSS

AAtttteennttiioonn ttoo aall ll rreeppaaiirrss ooff tthhee ccooaacchh HHCCRRSS

SSeenntt bbaacckk ttoo CCRR sshhoopp ffoorr ff ii ttmmeenntt ooff BBooggiiee bbyy ttrraavveerrsseerr && ttrraaccttoorr

HHCCRRSS

DD PPAASS SShhoott bbllaassttiinngg ooff ccooaacchheess ffoorr ''AA'' sscchheedduullee ppaaiinnttiinngg.. 11 66 PPaaiinntt sshhoopp

PPaaiinnttiinngg && DDrryyiinngg aass ppeerr SScchheedduullee wwii tthh SSpprraayy ppaaiinntt BBooootthh && OOvveenn -- uussiinngg ttrraavveerrsseerr ffoorr sshhii ffttiinngg//ttrraannssffeerr ooff ccooaacchheess

PPaaiinntt sshhoopp..

EE OOGGSS LLooaaddiinngg aanndd tteessttiinngg ooff eelleeccttrriiccaall ii tteemmss 22 88 TTLL sshhoopp

AAiirr BBrraakkee tteessttiinngg AABB sshhoopp

CCBBCC//BBuuff ffeerr hheeiigghhtt aaddjjuussttmmeenntt BBooggiiee rreeppaaiirr sshhoopp

FFiinnaall iinnssppeeccttiioonn CCRR sshhoopp,, NNCCWWSS//DDCCWWII

FF AACC AACC ccooaacchheess wwii ll ll bbee bbrroouugghhtt ttoo tthhiiss sshhoopp ffrroomm CCRR sshhoopp bbyy uussiinngg ttrraaccttoorr aanndd ttrraavveerrsseerr

1100 AACC sshhoopp

AAtttteennttiioonn ttoo aall ll rreeppaaiirrss ooff AACC ccooaacchh AACC sshhoopp

SSeenntt bbaacckk ttoo CCRR sshhoopp ffoorr ff ii ttmmeenntt ooff BBooggiiee bbyy ttrraavveerrsseerr && ttrraaccttoorr

AACC sshhoopp



- Let us now focus on body repair activities which are again time consuming. Let us see the activities which are to be done before we fix no of days coach would remain at this work station.

1 unit exchange of CBC Coupler -few hrs 2 unit exchange of buffers in DG Cars -few hrs 3 unit exchange of DV, air reservoir -few hrs 4 unit exchange of toilet fittings -few hrs 5 replacement of vestibule -few hrs 6 replacement of water tank -few hrs 7 replacement of door, window shutter -1 day 8 use of standard patches of SS sheet -1 day 9 replacement of berths -2 days 10 replacement of entire PVC in aisle portion -1 day 11 replacement of entire PVC in toilet -1 day 12 replacement of AL chequered plate in door ways -1 day 13 under frame scraping & painting -2 days 14 minor corrosion repair in under gear -3 days - Minimum no of days in body repair shop

- day 1 1,2,3,4,5,6,7,8,9,13 (s),14 (s) - day 2 10,11,12,13 (f) - day 3 14 (f)

- Bogie repair activities are to be done parallely along with body repair at different work station & are to be completed in 3 days.

Over the 10-12 years, innovations, improved maintenance practices and systems have been evolved for POH of LHB coaches in IR workshops. These are like "Islands of Excellence." An earnest effort has been made to incorporate these "Islands of Excellence", scattered in vast network of Indian Railways' workshops for finalizing a template for coaching workshop. Proposed Coaching Maintenance facilities aims to achieve quantum improvement in productivity by reducing cycle time of normal POH up to 18 days for LHB coaches. This will be possible with the application of latest concept/principles, M&P and technology. 8.0 Various defining principles/concepts utilized for developing ideal maintenance facilities for green field project are:

• Uniflow i.e. belt system of working for entire coach, bogie, wheels and

other assemblies. • Unit exchange of assemblies & components • Provide rather than produce • Replace rather than in-situ repair



• Outsourcing of non core activities & those activities which can easily be done outside

• Maintenance by OEM • Utilities/powered tools/balancer near work spot • Least movement of men & material • Outsourcing of cleaning activities or separate dirty / clean area • Coach over coach concept to induct flexibility in the process to ensure

uniflow of coaches from one work station to another work station. This would also ensure defined work at defined station leading to close monitoring of work done & improved quality.

• Traverser between paint booth & drying oven, needed as PU paint technology necessitates multiple movement of coach

• Separate heavy corrosion repair work center so that majority of coaches (80%) follow well defined process flow i.e. belt system

• Standardization like specified sizes of LP sheet, PVC. • Palletization • Modular working concept • Use of plasma cutting & CO2 welding • CBC/Buffer height adjustment by synchronized jacks in OGS

While this proposed template in its entirety could be very useful for green field project, the various concepts utilised in evolving this infrastructure, may also be used in brown field projects. The facilities and level of machinery to be introduced are essentially required to match the scale of POH work. A sample template has been developed for 5 coaches daily out turn; which includes 3 AC LHB coaches & 2 Non AC LHB coaches. Adequate space has been earmarked for future expansion also. The scope and type of mechanization to be introduced, has been selected from the ones, available in various Indian Railway workshops. The coaching infrastructure has been evolved by objectively evaluating the merits & demerits of various alternatives. In devising the layout, emphasis has been put on the enhancement of inspection/repair capacities and the shortening of the cycle time involved. Planning has been carried out from various points of view to implement these primarily objectives. This resulting plan is designed to facilitate the flow of coaches while fully utilizing maintenance infrastructure. This coaching infrastructure not only gives essential requirements for any LHB coaching workshop but also acts as a ready reckoner for variety of requirements including flooring, illumination, material stacking etc.



9.0 Salient features of Infrastructure: A. Major:

• Belt system of repair i.e. Uniflow system of working

• Coach over Coach concept

• Single Traverser serving Paint Shop, AC Shop etc.

• Jacks for buffer height adjustment & maintaining bogie clearances

• Cleaning operation by Shot blasting/outsourcing

B. Minor:

• Adequate time for attention (scrapping /corrosion repair/painting) to under

frame as coach body is on trestle for 2 days in Coach Body Repair Station,

leading to quality repair.

• Adequate time for bogie repair, leading to its quality repair.

• No pits in CRS, which would enable multi-purpose utilization of the shop floor,

and improve the transportation efficiency.

Such being the case, the disconnection/connection work required for the body

lifting/lowering will be carried out in ICS and OGS, which would be equipped

with pit.

• Adequate space (13 m) between Lifting/lowering lines of CRS.

• Adequate space (10 m) between two coach bodies kept on trestle in the repair

area of CRS for keeping tools and apparatus of various kinds and to keep sheet

metals of various kind & also to keep scrap bins & like.

• Provision of buried surface plate in HCRS to avoid warping of coach body.

• Coaches are being moved by pusher longitudinally and by traverser

transversely.

• Separate space for AC LHB coach testing.

• Use of Plasma cutting equipment and CO2 welding equipment in HCRS for

improved corrosion repair.

• A wide road parallel to railway track to facilitate easy transport of various

materials.

• Screen-printing of various numbers & letters on coach.



• The most important thing in the repair work is to find out the defective portions

of the parts completely. The rolling stock coming in for POH is considerably

dirty. Accordingly cleaning is important. The complete coach needs to be

cleaned thoroughly before it is taken inside the shop. The infrastructure also

suggests cleaning of various components (Bogie frame, Bolster, Springs,

control rod etc. by shot blasting (may be through outsourcing) on the pattern of

PER workshop & CRWS/BPL .

• Under frame of the coach body is full of rust, dust and muck. Inspection is just not possible unless it is thoroughly cleaned. An attempt has been made by CRWS/BPL to clean under frame by high pressure water jet. But this does not provide perfect solution.

Other workshops have adopted manual scrapping, which is quite tedious & laborious and does not give desired result.



Annexure-I

LLiisstt ooff iimmppoorr ttaanntt MM&&PPss rreeqquuiirreedd iinn rreessppeecctt iivvee sshhooppss WWoorrkk

CCeennttrree SShhoopp MM&&PPss NNoo.. ffoorr

55 CCPPDDOOTT

CCOOFFMMOOWW SSppeeccii ff iiccaatt iioonn NNoo..

CCRRSS CCRR sshhoopp 5500tt EEOOTT CCrraannee 22 CCOOFFMMOOWW//IIRR//EEOOTTCC//5500//22000044

AAiirr PPllaassmmaa ccuuttttiinngg mmaacchhiinneess

WWeellddiinngg mmaacchhiinneess

PPiillllaarr ddrriillll mmaacchhiinneess

CCiirrccuullaarr ssaawwss HHaanndd GGrriinnddeerrss

TTrriimmmmiinngg sshhoopp

SSeewwiinngg mmaacchhiinneess

PPVVCC GGrroooovviinngg mmaacchhiinneess

PPVVCC wweellddiinngg mmaacchhiinneess

PPlluummbbiinngg && WWaatteerr ttaannkk

sseeccttiioonn

SSccrreewwiinngg//PPiippee tthhrreeaaddiinngg mmaacchhiinnee

11 CCOOFFMMOOWW//IIRR//SSccrreewwiinngg mmaacchhiinnee//22000033

PPiippee bbeennddiinngg mmaacchhiinnee

11

HHaacckk ssaaww mmaacchhiinnee

11

AAlluummiinniiuumm wweellddiinngg mmaacchhiinnee

11

CCBBCC && DDrraafftt

HHyyddrraauulliicc HHoorriizzoonnttaall llooaadd tteessttiinngg mmaacchhiinnee

11 CCOOFFMMOOWW//HHTTTTMM//115500//22000044

MMaaggnnaafflluuxx tteessttiinngg mmaacchhiinnee ffoorr ddrraafftt ggeeaarr

11 CCOOFFMMOOWW//MMTTMM//DDGG//22000044

CCeennttrree llaatthhee 11 CCaarrppeennttaarryy

sshhoopp CCiirrccuullaarr ssaawwss 22

BBooggiiee rreeppaaiirr sshhoopp

1100tt EEOOTT CCrraannee--11 nnoo..

22 CCOOFFMMOOWW//IIRR//EEOOTTCC//1100//22000044

SShhoott bbllaassttiinngg ppllaanntt ffoorr bbooggiieess

11 CCOOFFMMOOWW//IIRR//BBooggiiee FFrraammee// SSBB//22000033

AAiirr lleessss sspprraayy gguunnss

22


BBooggiiee CCoommppoonneenntt sshhoott 11



CCoommppoonneenntt sshhoopp

bbllaassttiinngg ppllaanntt.. DDVV tteesstt ssttaanndd 22 PPiippee tthhrreeaaddiinngg mmaacchhiinnee

11

PPiippee bbeennddiinngg mmaacchhiinnee

11

HHaacckk ssaaww mmaacchhiinnee

11

CC'' ffrraammee HHyyddrraauulliicc PPrreessss

11 CCOOFFMMOOWW//CCHHPP--110000//8877

BBoosscchh ttaannkk ffoorr cclleeaanniinngg--ccooiill sspprriinnggss

11

AAiirrlleessss CCeennttrriiffuuggaall SShhoott bbllaassttiinngg ppllaanntt--ccooiill sspprriinnggss

11 CCOOFFMMOOWW//CCSS//SSBB//9977 ((RReevv--IIII)) ((22000033))

MMaaggnnaafflluuxx tteessttiinngg mmaacchhiinnee--ccooiill sspprriinnggss

11 CCOOFFMMOOWW//IIRR//CCSSCCDD//550000//9999

LLooaadd ddeefflleeccttiioonn tteessttiinngg mmaacchhiinnee--ccooiill sspprriinnggss

11 CCOOFFMMOOWW//IIRR//CCSSSSAALLDDTTMM--2200//22000044

PPrreessss ffoorr ddiissmmaannttlliinngg SShhoocckk AAbbssoorrbbeerrss

11

SShhoocckk AAbbssoorrbbeerr tteessttiinngg mmaacchhiinnee

22 CCOOFFMMOOWW//SSAATT//HHYYDD//990000//22000044

SSccrreewwiinngg//ppiippee tthhrreeaaddiinngg mmaacchhiinnee

11 CCOOFFMMOOWW//IIRR//SSccrreewwiinngg mmaacchhiinnee//22000033


HHaanndd GGrriinnddeerrss CCTTRRBB sshhoopp CCTTRRBB CClleeaanniinngg

PPllaanntt 11 CCOOFFMMOOWW//IIRR//MM//CCPP--RRBB//22000022

AAxxllee bbooxx sshhoott bbllaassttiinngg ppllaanntt

11 CCOOFFMMOOWW//IIRR//MM//CCPP--AABB//22000033

BBeeaarriinngg eexxttrraaccttoorrss

44

IInndduuccttiioonn hheeaatteerrss

44

ZZyygglloo tteessttiinngg ppllaanntt

11

CCRRSS WWhheeeell sshhoopp

CCNNCC AAxxllee TTuurrnniinngg LLaatthhee

11 CCOOFFMMOOWW//CCNNCCAATTLL//22880000XX330000//22000000

CCNNCC VVeerrttiiccaall TTuurrrreett LLaatthhee

22 CCOOFFMMOOWW//IIRR//CCNNCC//VVTTLL//11220000//0011



CCNNCC SSuurrffaaccee WWhheeeell LLaatthhee

22 CCOOFFMMOOWW//SSWWLL//BBGG//22000044

HHyyddrraauulliicc WWhheeeell PPrreessss--550000 TT

22 CCOOFFMMOOWW//IIRR//MM--HHWWPP//22000055//RR11

RRaaddiiaall DDrriilllliinngg mmaacchhiinnee

11

UUnniivveerrssaall AAxxllee JJoouurrnnaall TTuurrnniinngg && BBuurrnniisshhiinngg LLaatthhee

11 CCOOFFMMOOWW//IIRR//MMTT//JJTTBB--33--RR33--22000022((TTuurrnnkkeeyy))

UUllttrraassoonniicc ffllaaww ddeetteeccttoorrss

66

33tt EEOOTT CCrraannee 22 CCOOFFMMOOWW//IIRR//EEOOTTCC//33//22000044 PPAASS PPaaiinntt SShhoopp TTrraavveerrsseerr-- 7700 TT

ccaapp 22 CCOOFFMMOOWW//IIRR//MMHH//TTRRAAVV//22000000

ppaaiinntt BBooootthh 22 CCOOFFMMOOWW//IIRR//PPBB && BBOO// RRllyy..ccooaacchh//22000077 DDrryyiinngg OOvveenn 22

GGaarrnneett bbllaassttiinngg ppllaanntt

11

PPoolliisshhiinngg mmaacchhiinnee

HHCCRRSS HHeeaavvyy CCoorrrroossssiioonn rreeppaaiirr sshhoopp

DDoouubbllee ccrraabb EEOOTT CCrraannee-- 5500 TT ccaapp..

11

AAiirr PPllaassmmaa ccuuttttiinngg mmaacchhiinneess



CCiirrccuullaarr ssaawwss HHaanndd GGrriinnddeerrss

AACC AACC sshhoopp AAiirr PPllaassmmaa ccuuttttiinngg mmaacchhiinneess



CCiirrccuullaarr ssaawwss AAlltteerrnnaattoorr tteessttiinngg eeqqppttss..

CCoommpprreessssoorr tteesstt ppaanneell

HHaanndd ggrriinnddeerrss EEOOTT CCrraannee 22 TT ccaapp.. ffoorr RRMMPPUU

22

OOGGSS AAiirr BBrraakkee sshhoopp

SSiinnggllee ccaarr tteesstt rriigg

22



AAiirr ccoommpprreessssoorr ffoorr tteessttiinngg ooff AAiirr BBrraakkee ccoommppoonneennttss && ootthheerr uussee--CCaapp..3300MM33//MMiinn&& 1100KKgg//CCmm22..

11 CCOOFFMMOOWW//IIRR//EEAACC//SSCC//11000000//1100//0055

TTrraaiinn LLiigghhttiinngg

sshhoopp

AAlltteerrnnaattoorr tteesstt bbeenncchh

BBaatttteerryy cchhaarrggiinngg ppllaanntt

MMoottoorr wwiinnddiinngg mmaacchhiinneess


SSMMSS HHyyddrraauulliicc PPrreessss BBrraakkee--440000TT

11 CCOOFFMMOOWW//HHPPBB//440000//22000033

PPllaattee sshheeaarriinngg mmaacchhiinneess--66MMMM

33 CCOOFFMMOOWW//IIRR//DDCCGGSSMM//66 xx 33110000//22000011

PPllaattee sshheeaarriinngg mmaacchhiinneess-- 1133MMMM

11 CCOOFFMMOOWW//IIRR//DDCCGGSSMM//1133 xx 33110000//22000033

PPllaattee bbeennddiinngg mmaacchhiinneess

44

PPrrooffiillee ccuuttttiinngg mmaacchhiinnee

PPiillllaarr ddrriillll mmaacchhiinnee

33tt EEOOTT CCrraannee 11 CCOOFFMMOOWW//IIRR//EEOOTTCC//33//22000044 FFlloooorr ggrriinnddeerrss

BBHHAA SSyynncchhrroonnoouuss eelleeccttrriicc ooppeerraatteedd jjaacckkss-- ffoorr BBuuffffeerr hheeiigghhtt aaddjjuussttmmeenntt ((1155 tt XX 55 nnooss.. JJAACCKKSS iinn eeaacchh sseett))

33 sseettss CCOOFFMMOOWW//IIRR//EESSHHJJ//1155//9999



Annexure-II

BERTHING CAPACITY OF VARIOUS WORK CENTRES

Work Centre Shops Cycle Time in Days Daily Out turn Berthing

capacity

A CCS 0.5 5 3

B ICS 1.5 5 15

C CRS 3 5 25+25

D PAS 1 5 13

E OGS 2 5 10

Normal POH

90

F HCRS 10 1 10

G AC 10 1 15

IDEAL COACH HOLDING 125



Annexure-III DETAILS OF INFRASTRUCTURE FACILITIES PROPOSED FOR POH WORKSHOP FOR 200 LHB COACHES.

M&P required:

S.No Descriptions Qty

1 Synchronized electrically operated whitening jack 15 tonne capacity (Set of 5 nos.)

2 Sets

2 EOT crane – 40/30 tonne 2

3 Bogie load testing machine. 1

4 Rail cum Road vehicle for shunting 1

5 Coil spring scragging and load deflection testing m/c Cap 20 T for primary spring

1

6 Horizontal tensile testing machine for testing of CBC 1

7 Shock absorber testing machine with pc display and print out faculties 1

8 Load deflection testing machine with lateral measurement for flexi coil springs

1

9 Dynamic balancing machine- for wheel set 1

10 Grit blasting booth

11 Painting booth of one coach length with complete consisting of:-

i) Airless spray painting unit

ii) Full-fledge Effluent Treatment Plant

iii) Dedicated Compressor

iv) Winches for movement of coach

12 Oven for forced curing of paint coating

13 Fire fighting equipments

14 Paint/putty mixing/grinding machine, material handling trolley and ladles.

15 Inverter based AC/DC TIG welding machine 1

16 Synergic pulse Tag welding plants 8

17 Synergic Tag welding plant 2

18 Portable profile cutting machine 1

19 Welding rectifier 1

20 Milling machine 1

21 Pick & carry mobile crane 10 tonne 2

22 Static electronic Rail-road weighs bridge, for weighing of Coach 1

23 Hydraulic material carrying and lifting system – For lowering and 2



S.No Descriptions Qty carrying of CBC

24 Single car test rig for air brake system (fixed) 1

25 Single car test rig (mobile) RDSO sketch No. 81110 1

26 Test bench for distributor valve 1

27 Test bench for brake control panel 1

28 Simulator cum test bench CDTS 1

29 Press for removal of silent block 1

30 CTRB Extractor 2

31 Air plasma cutting machine 4

32 Pendulum action jig saw machine 1

33 Walk behind power vacuum sweeper 2

34 Vertical Hydraulic Press for primary suspension Part-12.613.0404 1

35 Bolster Beam Press Part- 2613037500 2

36 Mounting/Dismounting tool for Anti roll bar bearing 1

37 Hydraulic Scissor Trolley for mounting of Draft Gear 1

36 Grit Blasting & Epoxy Painting unit for FIAT Bogies 1

Tools & Equipments

1 Surface table 4mx3m-grade-2, IS- 2285- For alignment testing of LHB 1

2 Square drive torque wrench 4200 M1” male square drive for fastening of Nuts and bolts of Bogie frame.

1

3 Hydraulic torque wrench – For Nuts and bolts of Bogie frame 1

4 Torque wrench (ratchet) torque 38 Kg-m sq. drive ¾” 4

5 Torque wrench (ratchet) torque 3-14 Kg-m sq. drive ½” 4

6 Torque wrench torque 7-35 Kg-m sq. drive ½” and ¾” bit 4

7 Vernier dial calliper 0-300 mm 1

8 Vernier calliper 0 – 600 mm 1

9 Vernier Calliper 0-2000 mm, for inspection of bogie frame 2

10 Vernier height gauge 18” 1

11 Vernier calliper (digital) 1

12 Micrometer digimatic range 125 to 150 mm 1

13 Micrometer digimatic range 150 to 200 mm 1

14 Digimatic inside micrometer tubular range 175 to 200 mm 1

15 Digimatic inside micrometer tubular range 200 to 225 mm 1

16 Dry film thickness tester 1



S.No Descriptions Qty

17 Ford cup 4 No. 2

18 Gloss meter 2

19 Inside micrometer range 175-225 mm 2

20 Bench pillar drilling machine 1

21 Surface roughness comparator 30 specimens 1

22 Phased array ultrasonic flaw detector 1

23 Ultrasonic air leakage detector 2

24 Portable hand drill machine 2

25 Digital stop watch with split time 6

26 Tool cabinet As per requirement

27 Material handling crate ---do--

28 Trestles for coach body ---do--

29 Cleaning sink ---do--

30 Impact spanner ---do--

31 Pallet trolley ---do--

32 Feeler gauge ---do--

33 Allen key set ---do--

34 One meter stainless steel scale ---do--

35 12” stainless steel scale ---do--

36 Measuring taps 03 mtrs. ---do--

37 Steel rule ---do--

38 Heavy duty rechargeable torch ---do--

39 Helmet ---do--

40 Parallelism Check Tool as per part No. 12.841.0502 1

41 CBC APTA Gauges (both FTIL & Escorts make) 1 set each (set of 7 gauges)

42 Anti roll bar fork mounting fixture 1

43 Induction heater for pre-heating of Anti roll bar fork 1

44 Fixture for CBC supporting device maintenance 1

45 Ultrasonic thickness gauge for measurement of Bogie frame sole plate thickness

1

46



Annexure-IV A view of Pit line at DMRC on steel pillars:



Annexure-V

SCRAP DISPOSAL SYSTEM

1. Scrap is required to be segregated in different bins & trailer depending on

its type and amount of arising.

2. These bins will either be unloaded into dumpers or will be taken to

dumping point using Forklift.

3. Trailers will be picked up by tractor and taken to dumping point for

dumping.

4. Industrial waste comprising of PVC, LP sheets etc from nominated

dumping point will be sold out.

5. Ferrous/Non ferrous scrap will be sent to nominated store depot for

auction.



Annexure-VI

A. Automatic in-motion train washing system (ACWP) with water recycling plant

Description : Automatic in-motion coach/train washing plant for exterior, roof and under carriage cleaning with high pressure cleaning jet and with vertical and horizontal rotating brushing unit .

Source of supply : 1. M/s Wesurail - US 2. M/s Bingham – UK 3. Kokan Railway

Cost : Rs……./- lakhs

B. Photograph of Automatic in motion train washing system

Cleaning of coaches is the problem of the entire Indian Railways. Washing and cleaning of coaches is one of the though and critical jobs to be carried during train examination. The train movement on the such dusty/sultry climate of the region, to ensure desired level of cleanliness of coaches of Railways passenger trains is a real challenge. The rakes of these trains are examined and maintained at C&W Depot During examination of these rakes, internal and external cleaning and washing of coaches is being carried out. It is observed and studied that oily &



sticky smoke emitted by Diesel Locos especially in tunnels result in sticky soot and stains being formed on the coaches thus resulting in a real problem of cleanliness of the coaches and this has attracted public criticism also. As the staff is limited, the desired level of cleanliness cannot be done satisfactorily by conventional method within limited time period.

C. AUTOMATIC COACH WASHING PLANT

To overcome the above problem of coach cleanliness, a method of external cleaning of coaches by high-pressure water jet pump was adopted earlier. Seeing at number of staff involvement in carrying out coach cleaning, coach washing plant is developed by CAMTECH. In this plant, external cleaning of coaches of a rake was done at NGP, Madgaon & Kurla by horizontal rotating nylon brushes while passing through.

Eight powered nylon brushes were provided in this plant for the purpose of rubbing of soap solution and cleaning of dirt on external surface of coach .

1.Stages of

a) Pre-wash, b) Spraying of pressurized soap solution mixed with compressed air. c) After wash with high-pressure water jet were developed and

incorporated in this washing plant. In addition to horizontal nylon brushes, two Coir brush fixtures were developed and fitted in this plant. These coir brushes were static (non-rotating type) and fixed in one position for the purpose of even application and rubbing of soap solution on surface of coach, thereby sticky particles of soot and dirt get loosened and removed. But this coir brush could not touch and clean the area near window-sills, upper and lower portions of coach since upper portion of coir brush was obstructed by coach indication lamp, indication board, destination board and lower curved portion (turn under) of coach due to less stiffness of coir brush. Hence these portions were used to be cleaned manually by available staff.

This plant is developed with keeping in view the following points in mind. a) Less and economical maintenance of the modified washing plant.

b) Less manpower requirement for operation and maintenance this plant.

c) 95% exterior cleaning of a entire rake of 24 coaches is to be achieved within 35-40 minutes.



d) Reduction in water and soap solution consumption compared to the conventional Manual coach cleaning.

e) Reduction in power consumption by using automation.

f) Cleaning and disinfection of underneath portion of toilet by High pressure jets.

g) Bogie side cleaning by high pressure jets.

h) Roof cleaning of Coach by horizontal nylon brush. D. LAYOUT AND CONSTRUCTION OF AUTOMATIC COACH

WASHING PLANT

The modified coach washing plant is situated at the entry point of rake examination pit at coaching depot. There are four fabricated structures in this washing plant.

1) First structure is having plan area of 17sq.mtr. (5mX 3.4m) and provided for PREWASH stage. This structure is erected at a distance of 30 meter from second structure, to get complete soaking of coach with water.

2) Second structure is having plan area of 8.16 sq.mtr.(2.4m X 3.4m), is made from 300 x 150 mm ISBM & 300 x 90 mm ‘C’ channel This structure is provided for the stages of SPRAYING OF SOAP SOLUTION and Rubbing Of Soap Solution by vertical nylon brushes.

3) Third structure of underneath pipelines along with air and water reservoirs having plan area of (4.5mX3.4m) 15.3sq.mtr. and it is provided at distance of 16mtr. from second structure. This structure is provided for stages

of UNDERNEATH TOILET PORTION

and BOGIE CLEANING.



4) Fourth structure is having plan area of 48 sq.m.(14m X 3.4m) and provided for the stages of a) Moistening of soap solution b) Roof cleaning by a horizontal nylon brush c)Side cleaning by four vertical cotton brushes. d) After wash with high pressure jets. e)Mopping by two vertical cotton brushes. and Fourth structure is erected at distance of 23 mtr. from second structure, to get sufficient time for reaction and complete soaking

This structure is located at start of pit line is aligned and extended to old existing structure of coach washing plant. It is also made from same material used for second structure. Central apron already exists between the structure & track. It is provided with proper drainage and concrete apron in between structure and track and nearby area at all above locations so that waste water and soap solution will drain out immediately to adjacent main drainage and avoid adverse effect on sleepers and track. Due to proper apron and drainage, accumulated dirt and waste are easily cleaned and maintained with hygienic condition.

OLD STRUCTURE OF PLANT

RENOVATED STRUCTURE OF COACH WASHING PLANT



E.

Water is supplied from overhead tank of 40000 ltrs. capacity to underground tank of 10000 liters capacity (shown in figure). Water from under ground tank is supplied to coach washing plant for Pre wash and After wash stages, by 3 HP pump along with stand by, are located inside pump house. Soap solution is made in overhead plastic tank of 1000 ltrs. and this soap solution is supplied to coach washing plant for Spraying of solution stage, by one HP pump. Water pipe connections for Pre wash , After wash , Toilet and Bogie cleaning stages are made from 1" and 2" pipes and soap solution pipe connection is from 1" pipe. Electrical switchgears and control panel are provided for 3 Pumps (1 for soap solution and 2 for water),motors (each 3 hp)of 1 horizontal nylon roof cleaning brush and 6 vertical cotton brushes and 2 vertical nylon brushes for soap solution rubbing, in the pump house which is located near to washing plant. Compressed air supply, which is already available at pit line, is tapped for soap solution spray.

Both structures and vertical brush unit have been painted with two coats of epoxy primer and paint. Since this Iron structure and sub assemblies are more prone to corrosion due to existing salty weather and acidic/alkaline soap solution used in washing plant, epoxy painting is one of the better options to reduce corrosion and the cost.



F. PROCESS OF COACH CLEANING AND WASHING IN DIFFERENT STAGES

i. PRE-WASH: A rake is moving at speed of 5 KMPH during cleaning and washing of coaches through this plant. In this stage a diffuser type sensor is provided for sensing coaches of a rake. As soon as this sensor senses first coach of a rake, water starts spraying on external surface of coach through number of holes provided on water pipelines erected around in a row.

(a). SPRAYING OF SOAP SOLUTION: In this stage, diluted soap solution is sprayed on coach surfaces including two sides and roof through seven sprinklers. Provision is made for mixing of compressed air with pressurized soap solution inside the sprinklers to get more bubbles formed when it strikes with coach surface.

Two sides and roof of coaches are completely wetted by low velocity sprinklers at this stage, some loose dust & dirt is washed away from coach surface and simultaneously, coach surface is made uniformly wet, which help in even application of soap solution on coach body.

Due to release of surface tension in bubbles, dirt particles are loosened and washed away easily. Flow and quantity of soap solution can be controlled and adjusted by operating spindle nut on sprinkler and both valves provided on soap solution line and pneumatic line.



(c) SOAKING OF SOAP SOLUTION: In this stage, soap solution is allowed to soak completely for approx.1 minute in normal washing process. This stage is automatically achieved while rake is moving at 5 Km/h. through coach washing plant, since stage 3 and stage 5 is kept apart at 30 meter distance. During this stage, soap solution, is chemically reacted with dirt.

• • • • • • • • •

This pressurized spray clean underneath portion of toilet and near by area which is normally spoiled with wet soil. This process is also helping in prevention of breeding of cockroaches which generally take place in this area. Further, it also helps in maintaining hygienic conditions for working staff, who specially work or attend safety fittings in this portion of a coach. In this stage, sides of bogie are also cleaned by high pressure water jets simultaneously.

(b) RUBBING OF SOAP SOLUTION: This stage is especially incorporated to get more effective cleaning. In this stage, soap solution is rubbed and made even application on both sides of coach by two vertical nylon brushes one at each side of coach .This stage comes into action as soon as sensor at second stage is activated.

(d) CLEANING OF UNDERNEATH PORTION OF TOILET: In this stage, two sensors are provided for ascertaining the location of underneath toilet portion between two adjacent coaches by sensing of last wheel of first coach and first wheel of second coach. As soon as these sensors are activated in above situation, pressurized water mixed with disinfectant and phenol, sprayed from bottom through four nozzles which are provided between two rails.



(e) MOISTENING OF SOAP SOLUTION: In this stage, moistening of partially dried soap solution is carried out by sprinkling of very low-pressure water through number of nozzles provided on a water pipe line. Hence soap solution applied on roof and sides of coach become wet before rubbing by horizontal and vertical brushes.

AAff tteerr tthhiiss ssttaaggee,, CCooaacchh iiss mmoovviinngg ffuurrtthheerr tthhrroouugghh 44 sseettss ooff vveerrttiiccaall ccoottttoonn bbrruusshh uunnii ttss ((22 NNooss oonn eeaacchh ssiiddee)).. TThheessee bbrruusshheess aarree mmoovviinngg aatt tthhee ssppeeeedd ooff 115500 rrppmm.. DDuuee ttoo cceennttrrii ffuuggaall ffoorrccee,, eenndd ooff eeaacchh tthhrreeaadd ooff ccoottttoonn bbrruusshheess ssttaarrtt rruubbbbiinngg ssooaapp ssoolluuttiioonn oonn ccooaacchh ssuurrffaaccee wwii tthh ssmmooootthh iimmppaacctt eeff ffeecctt tthheerreebbyy wwhhaatteevveerr rreemmaaiinniinngg ssoooott aanndd ddii rrtt aavvaaii llaabbllee oonn ssuurrffaacceess aarree ttaakkeenn aawwaayy ccoommpplleetteellyy.. CCoottttoonn tthhrreeaadd hhaass ggoooodd ccaappii ll llaarryy pprrooppeerrttyy tthhuuss ii tt hhoolldd ssooaapp ssoolluuttiioonn ccoonnttiinnuuoouussllyy ffoorr lloonnggeerr ttiimmee.. TThheessee ccoottttoonn ttrreeaaddss hhaavvee ggoooodd ff lleexxiibbii ll ii ttyy aanndd ggeett rreeqquuii rreedd lleennggtthh aauuttoommaattiiccaall llyy aaccccoorrddiinngg ttoo sshhaappee ooff ssuurrffaaccee ooff ccooaacchh ssoo tthhaatt oonnllyy ttiipp ooff tthhrreeaaddss ggeett ttoouucchheedd wwii tthh ccooaacchh ssuurrffaaccee.. CClleeaanniinngg bbyy tthhiiss mmeetthhoodd hhaass sshhoowwnn ssiiggnnii ff iiccaanntt eeff ffeecctt.. TThheessee ccoottttoonn tthhrreeaaddss aarree ssppeecciiaall llyy ggiivveenn ssttii ff ffnneessss bbyy ffaasstteenniinngg wwii tthh nnyylloonn bbrriissttlleess ttoo pprreevveenntt mmiinnggll iinngg ooff ccoottttoonn tthhrreeaaddss.. TThheerreeffoorree,, ttiippss ooff bbrruusshheess aarree rreeaacchhiinngg ,,ttoouucchhiinngg aanndd ddooiinngg cclleeaanniinngg aatt iinnttrriiccaattee ppllaacceess oonn ccooaacchh bbooddyy ll iikkee wwiinnddooww,, wwiinnddooww ssii ll ll ,, wwiinnddooww sshhuutttteerr,, ddoooorrss ,, ssppaaccee nneeaarr ddoooorr iinncclluuddiinngg ddoooorr hhaannddllee,, ssppaaccee nneeaarr ttoo ddeessttiinnaattiioonn bbooaarrdd,, ttuurrnn uunnddeerr aanndd rrooooff ppoorrttiioonn.. EEaarrll iieerr,, tthheessee aarreeaa ccoouulldd nnoott bbee ppoossssiibbllee ttoo cclleeaann bbyy oolldd ccooaacchh wwaasshhiinngg ppllaanntt.. TThheessee bbrruusshheess aarree aallssoo hheellppiinngg iinn rreemmoovviinngg ooff rreesseerrvvaattiioonn cchhaarrtt ppaasstteedd oonn aa ccooaacchh..

(f) COACH CLEANING BY HORIZONTAL AND VERTICAL BRUSH ES: WWhheenn ccooaacchh iiss mmoovviinngg tthhrroouugghh tthhiiss ssttaaggee,, ff ii rrsstt rruubbbbiinngg ooff ssooaapp ssoolluuttiioonn ttaakkeess ppllaaccee aatt rrooooff ppoorrttiioonn bbyy hhoorriizzoonnttaall nnyylloonn bbrruusshh mmoouunntteedd oonn ttoopp ooff tthhee IIVVtthh ssttrruuccttuurree..



(a)MOPPING OF WATER : After wash, coach body become completely wet hence it require mopping. Two vertical brushes with soft cotton threads are provided each on either side. These brushes start mopping of water particles on sides of coaches as soon as coaches pass through these brushes.

This stage is specially effective for cleaning of AC glass windows where small water drops are always sticking and staining glass giving discomfort to passengers when they are looking outside through such windows. These brushes are also used for buffing of coaches to get shining by rotating it in dried condition when rake is moved from pit-line after examination. Since, requirement of soap solution is less for external cleaning of rake by this washing plant. Cost incurred in normal external cleaning of a rake of 21 coaches is Rs. 400 approximately. This cost includes cost of material like soap solution and cotton ropes (which are normally replaced once in a month) and cost of electrical power.

ii. AFTER WASH : In this stage, washing of roof and sides of coaches are carried out after rubbing of soap solution by vertical and horizontal brushes. High-pressure water is sprayed on coach surface through eight high-pressure sprinklers to wash coach completely. In this stage, washing of roof takes place just before washing of sides by spraying of water through high velocity sprinklers provided at top of structure. This arrangement is made purposely to allow dirty water after roof washing to flow down on both sides of coaches before washing of sides of coaches.



Annexure-VII INTERNAL COACH CLEANING MACHINE This machine is departmentally designed and developed for cleaning of coaches internally. It is operated on 220V AC as well as 110VDC supply thereby any coach lying any where in the yard can be cleaned by this machine as 110V DC supply available in a coach. Construction of this machine is sturdy and light in weight about 6 Kg hence it is easy to handle. Due to light weight and 1.2 meter length of machine, staff can do effective cleaning work in standing position without fatigue. At present, this machine is specially used for toilet cleaning and intensive cleaning of floor, berth, side wall by using various type of brushes.

FLOOR CLEANING BERTH CLEANING

WINDOW GLASS CLEANING TOILET CLEANING



Annexure- VIII

Flooring in the workshop: 1) Hardonate flooring

Hardonate flooring shall be provided for flooring generally in the Shop floor and path-ways. Specification for the hardonate flooring will be as under:-

For 9.29 sqm (100 sq.ft.) area to be provided with 38 mm thick top layer of hardonate flooring, 0.44 cum clean angular crush granite chip ¼” (6mm) down, 0.22 cum. of cement (approximate 6.34 bags) and mix in dry with 79.16 kgs. of hardonate compound. The hardening compound is Hardonate Fastonate or similar, of approved make. Necessary amount of clean water is then added to the mixture mixing the same thoroughly to form a steel workable mass. This mixture is now ready for laying the topping. The topping shall be kept damp for at least a fortnight. The construction point is to be filled with suitable bituminous material as directed. For 150 mm hardonate flooring, 38 mm thick top layer will be laid over 112 mm thick cement concrete base, which will be as per SOR A.

2) Cement concrete flooring M 25

This design of flooring has been done in the year 2002 at Permabur Carriage Workshop/Chennai. Specification for the cement and concrete are as under :-

Characteristic Comp. strength @ 28 days, Mpa : 25 Degree of control : Good

Mean Target strength @ 28 days, Mpa : 31.6 Workability Slump Initial : 125 mm After 60 mins. : 100 mm Max. Size of Aggregate, mm : 20 Cement : ACC (OPC) Fine aggregates : River sand Coarse aggregates CA I : Blue Basalt Coarse aggregates CA II : Blue Basalt Water : Well water Admixture : ConplastSP 430(S) Water cement ratio by weight : 0.47 Quantities per cum Cement : 403 kg Fine aggregates : 634 kg Coarse aggregate I : 341 kg Coarse aggregate II : 796 kg Water : 188 ltrs Admixture : 2.60 ltrs. Density of fresh concrete : 2362 kg/cum Laboratory cube strength obtained 7 days : 32 Mpa 28 days : 34 Mpa



200 Dewatering (Sucking out excess water) Rod Twisted Steel 200 Power trawling Φ 10 RTS @ 200 C/C both ways 150 RCC – Using Ready mixed concrete

80 Using 50 mm metal (broken rock jelly)

230 Soling Stones 3) Epoxy flooring

Epoxy resin flooring is more resistant to mechanical wear and chemicals. Such flooring can be provided in Paint Shop, RB Shop and Lifting/lowering Sections.

The properties/specifications for epoxy flooring will be as under:-

The epoxy resin shall be applied on epoxy primer whilst it is still tacky. It shall offer a minimum compressive strength of 50N/mm², flexural strength not less than 12N/mm² and a minimum tensile strength of 4.5 N/mm², when tested as per BS6319. It shall not register a loss of more than 170 mg for 100 cycles of the abrader wheels, as per ASTM D 1044, for abrasion resistance. When tested as per ASTM D 256 for impact resistance, it shall give a minimum result of 1.3 kg.cm./ cm². When tested for flame retardation as per UL-94 HB, it shall be self extinguishing. It shall also give a minimum hardness of 98 as per ASTM D785 Rockwell hardness test. It shall have a minimum bond strength of 3 N/mm² to concrete.

4) Eco-friendly sheets/Crib Flooring This being acid resistant, would be most suitable for Battery section. Details are

specified in RB’s letter no. 2005/Elec(G)145/3 dt 31.5.06



Annexure- IX

Illumination Level (recommended by RDSO and IS 3646 Pt.II-1966, published in IRIEEN Journal 3(1993)-1)

Minimum illumination in LUX should be as under:- S.No. Industrial Buildings Illumination in lux 1. GENERAL FACTORY AREA A) Canteen 150 B) Clock Room 100 C) Entrance, corridors and staircase 100 2. ASSEMBLY SHOP A) Rough Work – Frame Assembly 150 B) Medium Work – Machine Parts & Engine Assembly 300 C) Fine work – Radio Telephone Equipments Type Office Machinery 700 3. Laboratories Electrical and Industrial 450 4. Machine and Fitting Shop A) Rough Bench and Machine Work 150 B) Medium Machine Works (Rough Grinding, Medium Buffing, etc.) 300 C) Fine bench Machine Work 700



Annexure- X

Roofing in Workshop: 1. Aluminium roofing should be provided as provided in RCF/Kapurthala. The details as

per IRCON Drawing No. 55.RS.115.G to 55.RS.137.B (Total 23 Nos. drawings). Sketch indicating the major parameters of roof details to be collected.

2. Aluminium zinc alloy roofing has been provided at Perambur Carriage Shop. The

design details and specifications of the same are as under:-

A. Metal coated sheets of aluminium zinc alloy (Galvalume 150 gms.Sq.m. total of

both sides, AZ 150 as per ASTM A 792 or AS 1397) in roofing not less than 0.50 mm thickness (Overall). The material shall have yield stress of 550 Mega Pascal (MPA) for sheets in roofing, in Capping (ridges), Valley (Flashing), barge boards with one crest width including lip as side lap and 150 mm as longitudinal lap for each sheet with fixing accessories like self drilling screws, caps, having EPDM (Ethylene Propylene Di-Monomer) Washers, PVC caps of matching colour with roofing sheets, duly coating the sheets with top polyester coating with medium gloss or egg shell finish of thickness 20 micron over a back and primer coat of 5 to 10 micron each duly getting the colour scheme of sheets approved.

1. Roofing: 1.1 Providing and fixing Lloydeck Hi-Rib profile or similar colour coated galvalume

sheet, 975-1000 mm cover width, 26 + 2 mm crest height at 195 – 200 mm centres, in lengths upto 10 m to suit site requirements.

1.2 The material shall be Cold Rolled Steel, 550 MPA – yield stress with hot dip metallic coating of aluminium zinc alloy (Galvalume 150 gms/sq.m. total of both sides, AZ 150 as per ASTM A 792 or AS 1397) or equivalent. 1.3 The total coated thickness of the profile sheet shall be 0.5 mm including polyester coating (SMP – Silicon Modified Polyester Coating).



2. Fixing: 2.1 Roofing sheets shall be factory cut and supplied in required lengths (of upto 11 m) to suit shop drawings. 2.2 Roofing sheets shall be crest fixed to purlins with hop dip galvanized self drilling fasteners with integral EPDM washers (One fastener on each crest). 2.3 Also, fasteners to be provided on the side laps with one crest width including lip with minimum sheet overlap at end laps shall be 150 mm. 2.4 Penetrations and end laps in sheet shall be seated by using proper sealant. 2.5 Profiled HDPE fillers shall be provided wherever required to close voids between cappings and troughs of the sheet to provide a weather tight exterior.

B. 10 mm thick Lexan or equivalent Twin walled Polycarbonate clear sheets of

standard size for North light glazing to suit the existing structural runner inclusive of fixing Flexi clamp aluminium glazing bar, bolts tuds, buts washers, cleats, shoes, etc. including all lead and lifts etc.

C. 2 mm thick Lexan or equivalent embossed Polycarbonate clear sheets for strip

lighting in roof to suit the same profile of metal coated sheets used in roofing with one crest width including lip on one side and crest on other side with 150 mm longitudinal lap per sheet inclusive of bolts and nuts neoprene washers/Self tapping screws with suitable washers etc. including all lead and lifts etc.

1. Strip Lighting 1.1 Lexan or similar type embossed clear Polycarbonate sheets 2 mm thick to match the profile of metal coated sheets shall be used. 1.2 Width of the profiled Polycarbonate sheet shall be 0.80 to 1.20 metre wide and a maximum length of 3.00 metre with over lap on either side in metal coated sheets equal to one crest width and lip on one side and one crest width on other side with a minimum longitudinal lap of 150 mm per sheet. 1.3 Fixing shall be done with bolts and nuts neoprene washers/self tapping screws with suitable washers as required. 1.4 The work shall be executed in high roof shed which involves carrying of materials, hoisting in position upto the desired elevation as directed and approved by the Engineer-in-charge. 1.5 The work shall also include hiring of tools, plants for the work using scaffolding materials required for erection at contractors own cost.

2. Side Cladding/Louvers: 2.1 Lexan or similar type embossed clear polycarbonate sheet 2.00 mm thick to match the profile of metal coated sheets shall be used in side cladding and in louvers. 2.2 Width of the profiled polycarbonate sheet shall be 0.80 to 1.20 m and lengths required varying upto 3.00 metres and standard laps equal t one crest width and lip and a longitudinal lap of 150 mm per sheet.



2.3 The work shall be executed in high roof shed which involves carrying of materials, hoisting in position upto the desired elevation as directed and approved by the Engineer-in-charge. 2.4 The work shall also include hiring of tools, plants, for the work using scaffoldings material required for erection at contractors own cost.



Annexure- XI Air Ventilation System:

This Express air ventilation system would be very useful in old shops to improve ventilation & illumination. The wind velocity spins the vanes which causes a region of low pressure which in turn draws hot air out. The slightest breeze will cause the turbine to spin. Suction is maintained even at low wind velocities. The convective thermal currents are given further boost by venturi dome to further enhance the rotation of the system. This system will be able to exhaust trapped hot air, chemically polluted air, steam, gas, and powder & dust particles. This is a simple, light weight construction, easy to install, noise free & weather proof system. This system comprising of 60 ventilators has been installed at corrosion shop of Lower Parel workshop of WR at a cost of Rs 3.6 lakhs by M/S Express Engineering Construction Ltd GIDC Baroda. Contact person Mr S.V.Kori (09819744355).



Annexure- XII DETAILS OF EOT CRANE:

PARAMETERS OF EOT CRANE

1 Description : Double Crab EOT Crane

2 Capacity

Main Hoist : 25t x 2 crabs Aux. Hoist : 7.5t x 2 hooks

3 Span : 30 Meter

4 Height from the floor to the top of gantry rail

: 12.5.Meter

5 Bay length : 96 Meter

6 A.T No. : COFMOW/IR/S-3743/2K/OP-1097 dt. 04.09.01

7 Supplied by : M/s. Unique Industrial handlers Pvt. Ltd, Mumbai.

8 Cost : 80.93 lakhs each.



Annexure- XIII

Coach over coach system in maintenance Bays



Annexure-XIV

TRANSPORTATION CODES FOR LHB COACHES

Sr.No TYPE OF LHB COACH CODE

1 AC FIRST CLASS SLEEPER- (EOG) LWFAC

2 AC FIRST CLASS SLEEPER- (SG) LWGFAC

3 AC SECOND CLASS SLEEPER- (EOG) LWACCW

4 AC SECOND CLASS SLEEPER- (SG) LWGACCW

5 AC THREE TIER CLASS SLEEPER- (EOG) LWACCN

6 AC THREE TIER CLASS SLEEPER- LACCN (SG) LWGACCN

7 AC DOUBLE DECKER AC CHAIR CAR (EOG) ACCC DOUBLE DECKER

8 AC HOT BUFFET CAR LWCBAC

9 LHB GS EOG coach fitted with the new inner spring design of secondary suspension (LW05127) with a combination of existing LG05101 outer spring (Shalimar coach secondary outer spring) and Rubber spring with 36 mm shim.

LS4

10 NON AC SECOND CLASS THREE TIER–(SG) LWGSCN

11 NON AC- LUGGAGE CUM GUARD VAN(SG) LGSLR

12 AC CHAIR CAR EXECUTIVE CLASS LWFCZAC

13 AC CHAIR CAR LWSCZ AC

14 GENERATOR CUM LUGGAGE& BRAKE VAN LWLRRM

15 EOG NON AC HOT BUFFER LHB COACHES LWCB

16 EOG AC FIRST CLASS CUM AC TWO TIRE LHB COACH LWFCACCW

17 II class non-AC EOG LHB variant in BG coach fitted with modified suspension on FIAT bogie with suspension to Drawing No. LG 90018 with 32 mm shims without 2 under slung water tanks of 685 Lt capacity, luggage rack shifted upward by 440 mm.

LS 2`

18 II class non-AC EOG LHB variant in BG coach fitted with modified suspension on FIAT bogie with suspension to Drawing No. LG 90019 with 32 mm shims without 2 under slung water tanks of 685 Lt capacity, luggage rack shifted upward by 440 mm.

LS 3

19. EOG non AC chair car LHB variant coaches fitted with FIAT bogie with 16.25 t axle load

LWSCZ



Annexure-XV

Shopwise Summary of Parameters



Suggestions given by Zonal Railways for Infrastructural facilities in

POH Workshops during seminar on 20.07.2015.

1. Length of CCS should be increased to 100 meters 2. Height of all sheds of shops should be increased to 15 meters 3. ETP plant & Water Recycling plant should also be provided for CCS shop 4. Dismounting of Bio-Toilet tank should be added in the activities of ICS shop 5. Depth of pit line in OGS shop should be kept as 1.3 m for final inspection of under

gear. 6. Pneumatic tools should also be included in the list of tools in line with PER

workshop. 7. Modified test bench(computerised) for DV testing of LHB coaches should be

provided in Air Brake shop. 8. Model lay out drawing for Workshop should be communicated to existing LHB

Workshops for offering comments/suggestions.

Dra ft R eport on Infrastructural Facilities Required in ... Report on...

Documents

Transcript of Dra ft R eport on Infrastructural Facilities Required in ... Report on...