Quality Audit Report Of Coaching Depot New Coaching

Transcript

Quality Audit report Of Coaching Depot New Coaching Complex,(Sealdah), Report no. 16/2012 APRIL 2012 (Audit is done by QA Mech Dte of RDSO ) E Rly Quality audit Report of NCC Coaching Depot, Eastern 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. Quality audit of NCC Sealdah has been done by Director/QA(Mech), Kolkata 1.1 Audit team - S/Sri M A Alam, Director/I&L/Kolkata, S Bose, AIE/I&L/Kolkata and B K Sahoo, JE/I&L/RDSO/Kolkata 1.2 Date of audit - 7.04.2012 & 14.04.2012 1.3 Escorting officer from depot - Sri Yatish Kumar, Sr DME(C&W)/SDAH & Sri Ranjit Roy CDO/SDAH and concerned SSE/C&W/NCC of depot. 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, A and 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, Sr DME/C&W/SDAH and his team was briefed about observation noted during audit. 2.0 Brief about visit New Coaching Complex, Sealdah with a holding of 794 coaches is a major coaching depot of Eastern Railway. Total 6 pit lines with catwalk are available to carry out primary maintenance of Mail/Express trains such as Sealdah Rajdhani, Duronto Exp, Darjeeling Mail, Akal Takht Exp, Annaya Express, WB Sampark Kranti Express and important Mail/Express train to North Bengal starting from Sealdah station.Depot is also maintaining one DEMU service consisting of 8 coaches. During two days of audit, items as per scope of audit have been checked alongwith relevant records. Infrastructure availability in the coaching depot and planning of inputs has been studied. The escorting officers and supervisors have given full assistance to audit team and escorted audit team during audit. Page 1 of 36 Coaching depot – NCC - (Sealdah), E.Rly. April 2012 3.0 Strengths 3.1 Depot has provided LED destination board in 159 coaches of important Mail/Express trains against RSP. Rajdhani Express (12313/12314), Duronto Express (12259/12260), Ananya Express (12315/12316) and Akal Takht (12317/12318) and WB Sampark Kranti Express (12329/12330) have been provided with LED destination board (including spare coaches). 3.2 Depot has installed one mechanized laundry as per RB’s guidelines. Total 3500 packets are washed daily from this mechanized laundry. Quality of washed linen is satisfactory. 3.3 Depot has displayed a list of official with name and mobile number to address various complaint from passenger. They are getting regular feedback from passenger and issues are addressed immediately which enhance passenger satisfaction. Name of the cleaning inspector with mobile number has also been made available on trains provided with OBHS. 3.4 OBHS through outsourcing as per RB’s guidelines has been provided on 7 important Mail/Express trains Viz. LHB Rajdhani (SDAH–NDLS), Duronto Exp (SDAH–NDLS) & other important M/E trains. Depot is providing OBHS in SDAH–Puri Duronto by deploying C&W staff. This has resulted in passenger satisfaction. 3.5 Depot has awarded mechanised cleaning contract for all cleaning activity of coaches. Good quality cleaning solutions of Jhonson Diversity make such as Taski Spiral F 11Y – Floor cleaner concentrate, Taski R7 for LP sheet/Rexene cleaning and Taski R1 Super – Bath room cleaner cum sanitiser concentrate are used during coach cleaning and disinfection. Contractual agency is providing equipments also for cleaning work. 3.6 Depot is carrying out buffing operation in SS basin, SS top of pantry car and toilets squatting pan due to which surface shine is maintained. This has enhanced passenger satisfaction. 3.7 Depot is providing epoxy flooring (Floor kote) in toilets of coaches where PVC flooring has been found in damage condition and coach is not due for IOH/POH. This is being carried out through in-house and material has been taken from LLH shop (Floor Kote is stock item of LLH depot) 3.8 Depot is carrying out maintenance of CDTS fitted in LHB coaches through inhouse and all CDTS are working. Spares are procured through OEM. 3.9 Depot has established proper garbage disposal system. Refuses/left-over food from all Pantry cars and refuses from coaches of OBHS operated trains are collected at Platform after arrival of down trains. Refuses / garbage’s are disposed from station. This has resulted in minimum accumulation of garbage at depot during PM of rakes. All pantry equipments are downloaded at Page 2 of 36 Coaching depot – NCC - (Sealdah), E.Rly. April 2012 platform in each trip. This has ensured proper cleaning and pest control of pantry car and minimizes pest/rodent compliant during last six month. 3.10 Supervisor and staff are trained. Depot has good safety performance and there is no derailment / accident on C&W account. There is no en-route detachment of coach during 2011-1 2. 3.11 Depot has adopted an effective rodent control system. Rodent control measure has been adopted for en-route treatment also by providing glue board and specially designed rat traps in coaches. In addition rodent control measure is taken during primary maintenance of trains. Depot has adopted effective monitoring of pest control measure during last seven months and passenger complaint on account pest / rodent reduced to 3 complaints from Sep’11 to Mar’12 against 22 complaints from Apr’11 to Aug’11. 3.12 Depot has adopted a feedback system for quality of linen from coach attendant. Feedback for each coach in a rake is submitted in standard format by CA. Feedbacks collected through CA is computerised and assessed by Depot officer and supervisor for taking corrective and preventive action. 4.0 Weaknesses 4.1 Blankets were being washed at two months interval and depot has switched over to dry cleaning at one month interval from Apr’12 onward only. 4.2 Curtains were being cleaned at one month interval. Depot has switched over to cleaning at 15 days interval from Apr’12 onward only. 4.3 Adequate space is not available for linen handling & stocking. Stacking of washed and used linen items as well as new linen items received from store is not adequate. FIFO is not being applied. 4.4 Depot is not aware regarding list of safety items published by RB and following their own list of safety items. Store is congested and stocking of store is not adequate. FIFO is not applied. Depot has no separate AMM for procurement of urgent store (Safety and passenger amenities items) with adequate ceiling limit. Presently procurement is being done by divisional store officers or by HQ. CDO/SDAH has a cash imprest of Rs.30000/- only. 4.5 Pest control is awarded to CP pest control which has already expired and further extended. Depot has yet to award contract as per model contract for pest control issued by Railway Board. Tender is under process. Performance of existing pest control agency is not satisfactory. Depot has taken some additional initiative on its own for pest & rodent control management. Sealdah Division has not taken any rodent control measure for platform area. Rodent control measure is available for depot area only. 4.6 Rolling-in examination of terminating trains is not adequate. Staff deployed for rolling-in is not adequate. Records of rolling–in examination have been checked on 14.04.12. Temperatures of all axle boxes have been recorded in register. No other defects pertaining to defects of under-gear during rolling-in examination have been recorded in register. Page 3 of 36 Coaching depot – NCC - (Sealdah), E.Rly. April 2012 4.7 Manpower available for under gear examination is 533 staff against requirement of 587 staff. Manpower available for sick line attention is 148 staff against requirement of 156 staff. 4.8 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. Snack table in NAC coaches are provided directly over L.P sheet and this gets worked out during service. 4.9 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 is not being prepared. 4.10 For IOH attention at depot, record is maintained for under-gear attention only. Record for upper body attention is not maintained. For IOH attention at shop, no record for attention of under-gear and upper-body is available. Overdue IOH is 19 coaches. 4.11 FAC (7 coaches) and composite AC (7 coaches) are provided with upholstery. Contract to carry out upholstery cleaning has expired and new contract is yet to be awarded to professional agency. Presently work is being carried out through mechanised cleaning contract. 4.12 D3 schedule of LHB coaches (six monthly schedule attention) is not adequate as coach is not detached from rake for attention in sick-line. Attention is given at pit line in rake. 4.13 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 is not done for rear end seal at depot. 4.14 Depot has single neck for shunting operation due to which detachment and attachment of coach in rake takes much longer time. Other end of pit line has dead end. 4.15 Existing sick line at NCC depot has no crane facilities. Wheels are unloaded through hoist arrangement. Lifting is being carried out through JMP jacks. Catwalk and pits are not as per CAMTECH design. Total 6 deep pits with catwalks were constructed when CAMTECH design was not finalised. Width of catwalk is less. Depot has two stabling line which will be converted to two deep pits with catwalk. To overcome infrastructure shortcomings, the following works have been sanctioned and works are in progress:    Sick line of 102 m X 24.2 meter length over 4 lines with one overhead crane of 25 T facilities is under construction at NCC depot. One pit wheel lathe is under installation for coach turning. Two deep pits (24 coach and 22 coach length) of CAMTECH design are under construction. Page 4 of 36 Coaching depot – NCC - (Sealdah), E.Rly. April 2012     4.16 Light weight cover shed over 8 deep pits for all-weather maintenance pits. Double storied service building. 6 nos washable apron ( 3nos at NSS yard and 3 nos at Kolkata Goods Yard). Peripheral concrete road for material movement. Shortcomings have been noted in area which is not directly attributed to depot but need attention at respective level for better performance of coaching depot and reliability of rolling stock Total 81 wheel sets attended in 2011 -12 due to canted (12 cases), grease oozing (15 cases), Grazing with wheel (9 cases), warm and hot (3 cases) and other (cover, axle box wing etc) – 11cases. Grease oozing out may lead to hot axle en-route.  For en-route watering, adequate time at en-route watering station has not been provided. As reported by depot, SDAH Rajdhani 12313/12314 has only 10 mts stoppage time at MGS for coach watering.  For facilitating inspection of sole bars, even-spaced elongated holes of (215x127 mm) have not been provided in the turn under of all coaches. One coach in sick line has been checked and observed that coach ER 10107 (built RCF & POH/LLH- 16.02.12) is not provided with elongated holes of 215x127 mm size.  Major contribution of primary detachment is tank leaky (16.03%), Brake cylinder (10.7%), Main/Lugg/Lav door (10.03%), Wheel sets (9.34%), Bk rigging (6.9%), draw & buffing gear (5.99%). This need attention by respective POH shop. Facility for water tank testing is not available at depot. This is required to avoid repeated attention of leaky water tank.  Depot has awarded contract for disc brake (including air brake) attention in LHB coaches for KB makes brake system only. Contract for Faively Transport make disc brake system has expired. Depot is carrying out maintenance attention of FTIL make phonic wheel / speed sensor thorugh in-house. Contract is yet to be awarded on FTIL to keep the disc brake system in good condition. As reported by depot, shop is not attending disc brake system during POH / IOH attention as contract with KB and FTIL has expired and new contract is yet to be awarded by shop.  Primary dampers in some LHB coaches are defective which resulted in loosing of mounting bolts of control arm during service. Mounting bolt is tightened regularly during PM. Depot is not getting dampers against indent placed on RCF. Depot has received only 18 primary dampers during 2011 – 12.  LHB Wheel sets are cannibalised during maintenance and wheel sets sent to shop when due for CTRB attention (at 3 years interval or 12 Lakh Km). As per RB guidelines, coaching axle need to be given UST Page 5 of 36 Coaching depot – NCC - (Sealdah), E.Rly. April 2012 at one year interval. Presently attention is given to axle for UST when wheel sets touch the workshop. IOH attention is given at 18 months interval. It is also observed that no attention is given for UST of axle at depot and wheel sets with life of more than 2 years are in service without UST of axle. Due to absence of guidelines for LHB wheel sets, depot is not attending wheel sets for UST of axle.  Depot has reported some major defects in recently received LHB coaches for Duronto Express. RCF has been informed by Zonal Railway (ER). Summary of observations reported by depot is as under:               Page 6 of 36 Outside basin, mirror, liquid soap dispenser have not been fitted in 1st AC coaches. Attendance seat in 2nd AC has not been fitted. Some coaches are not provided with protection cover in air brake panel. Two coaches are provided with PVC flooring in gangway area in front of toilet. In all other coaches, the PVC flooring has not been done up-to edge of the gangway. Gap between berth and bracket have been observed in 4 coaches. C/No. 11054, 11108, 11111, 11053, 11002, 11001, 11051 are fitted with gap in the toilet door. The latches provided in 1st AC are made of mild steel on wooden base. Vestibule door sliding arrangement cover is not provided in Coach No. 11802 (KPA – end). Inside wash basin: Some coaches were not fitted with rubber molding. Outside wash basin: Both design with molding and without molding are being fitted. Sharp edges of the door have been observed and removed through grinding by representative of RCF at SDAH depot. Upper berth bracket: Coach No. 11116 (No. 35), 11108 (No.62 & 67), 11111(No. 14, 19, 22, 27, 38 & 43), 11118(No. 6, 11,14,19,22, 27, 43, 46 & 51) are provided with sharp corner brackets which are unsafe for passenger. Upper berth fitted without roundness on corner Side wall panel 1st AC: Gap observed and Aluminium foil visible Coaching depot – NCC - (Sealdah), E.Rly. April 2012 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: New coaching Complex, Sealdah Date of audit: 07.04.2012 SN Item 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 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. Schedule A - Monthly (1 month ± 3 days) in rake Schedule B -Quarterly (3 month ± 7 days) in rake IOH attention - detach coaches Periodicity of IOH attention: Coach Periodicity Category at interval of 12 New coach months in Depot 112(a) of Chg. Manual an Correction slip 5 for coaching maintenance manual issued in 2008 3 4 5 Rajdhani Satabdi (Conv) Mail / Express Passenger Other OCVs Clause at interval of 9 months in workshop at interval of 9 months in depot at interval of 9 months in depot 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 Page 7 of 36 RB letter no. 2007/M ( C)/141/1 dtd 26.09.08 Observation Periodicity of POH as per Railway Board’s guidelines is followed. ICF NAC coaches are given POH attention at KPA shop and ICF AC coaches are given POH attention at LLH shop. Status of POH attention during 2011 - 12 is as under: POH at LLH shop: 97 POH at KPA shop: 414 Overdue POH as on 01.04.12 is nil. NCC Depot/SDAH has a bare holding of 701 coaches and total holding of 794 coaches (including maintenance spare and traffic spare). ICF coaches – 656, LHB ( including Duronto) – 111, ICF(Duronto) – 19 & DEMU - 8 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. During last months, Total A schedule carried out : 3592 Total B schedule carried out: 864 Overdue A and B schedule: NIL Existing sick line at NCC depot has no crane facilities. IOH attention is given at KPA /shop and Kolkata terminal (Chitpur) depot. LHB coaches and AC coaches are attended at LLH shop. Newly built coaches (ICF design) are attended at Depot as per Board’s guidelines. During 2011, status of IOH attention for ICF design coach is as under: IOH attention at KPA shop IOH attention at LLH shop IOH attention of newly built Coaching depot – NCC - (Sealdah), E.Rly. April 2012 190 76 88 SN Item vide RB’s letter no. ( C)/141/1 dtd 06.08.09 Clause 2007/M 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. 6 112(b) of Chg.Manual Observation coaches IOH attention of pass. 8 coaches Overdue IOH coaches: 19 Existing Sick line at NCC depot has facility of 10 coaches under cover shed and wheels are unloaded through hoist arrangement. Lifting is being carried out through JMP jacks. Total 12 nos whiting jacks are available at sick line. Sick line of 102 m X 24.2 meter length over 4 lines with one overhead crane of 25 T facilities is under construction at NCC depot. One pit wheel lathe is also under installation for coach turning. This is being followed. The depot is carrying out the following attention at depot: Mail Express trains PM with RTM at other end 13 PM with SM at other end 04 RT attention (other base) 03 RT attention (own base) 03 Passenger trains PM with RTM at other end 08 Total attention 31 Total 15 coaches are missing over Foreign Railways. These coaches returned to base depot when due for POH. Examination of originating trains: 7 7.1 8 All trains must be examined by the mechanical train examining staff before despatch to ensure all coaches are in fit condition without rejectable defects. Terminating Examination of Passenger Trains – Rolling in examination. 107 a of Chg. Manual 107 a (i) of Chg. Manual 107 b of Chg. Manual 8.1 Site shall provide unobstructed view of under gear from both sides. 107 (b)(i)(a) of Chg.Manual 8.2 Should have adequate space for fixing the lighting arrangement and for staff 107 (b)(i)(d) of Chg.Manual 8.3 As the train passes the nominated 107(b)(iv) of Chg.Manual Page 8 of 36 This is being followed. All trains are examined by C&W staff before despatch. Rolling–in examination is being carried out at SDAH station. Deployment of staff have been checked during audit and found only 2 men deployed for rolling-in examination. Site has un-obstructed view of under gear from both side. Lighting arrangement for rolling–in examination is available. 06 nos of light are fitted in three lines covering all in-coming Mail/Express trains. One light for line no. 5 is not working. Deployment of staff for rolling-in is inadequate. Records of rolling – in examination Coaching depot – NCC - (Sealdah), E.Rly. April 2012 SN Item Clause 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. 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 9 Revised maintenance pattern for coaching trains circulated vide Railway Board’s letter No.95/M(C)/141/1 dt.31.01.07 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. Primary End Railway Board’s letter No.95/M(C)/141/1 dt.31.01.07 9.1 9.1.1 Railway Board’s letter No.95/M(C)/141/1 dt.31.01.07 Observation have been checked. Temperatures of all axle boxes have been recorded in register. No other defects pertaining to defects of under-gear during rolling-in examination have been recorded in register. Axle box temperature is measured with non contact type temperature measuring device. 08 nos noncontact infrared temperature measuring device is available at PF. This is being ensured. The brake gearing should be properly adjusted including the slack adjuster ‘A’ dimension & the brake cylinder stroke to ensure 100% brake power Brake blocks should be changed in bogie sets only All missing passenger amenity fittings must be replaced and the rake must be turned out as ‘ZeroMissing-Fitting’ rake. -do- ICF Coaches have been provided with BMBC. Piston stroke is adjusted to 32 mm during primary maintenance. -do- This is being ensured. -do- Intensive cleaning of coach toilets and lavatory. Clear maintenance time of 6 hours on the pit as per train schedule. -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 shop is not providing these items in Non AC coaches. Snack table in NAC coaches are provided directly over L.P sheet and this worked out during service. This is being ensured. vi) Provision of proper washing cum maintenance pit line facility with adequate testing equipment and high pressure jet cleaning plant at primary end. -do- vii) Adequate gang strength proper supervision -do- i) ii) iii) iv) v) Page 9 of 36 with -do- Clear maintenance time of 6 hrs on the pit is available as per train schedule. NCC has total 6 deep pits with catwalk and washing apron. 10 nos. RTR is available for air brake testing. High pressure jet machine is available for coach washing and toilet cleaning. Cleaning activity has been outsourced (100% outsourcing). Manpower available for under gear examination is 533 staff against requirement of 587 staff. Manpower available for sick line Coaching depot – NCC - (Sealdah), E.Rly. April 2012 SN Item 9.1.2 i) ii) iii) 10 11 12 12.1 12.2 Clause Observation attention is 148 staff requirement of 156 staff. against The Other End 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. The minimum infrastructure to be provided at the platforms from where trains are returned without secondary maintenance should be is available 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. Rake maintenance link has provision of maintenance time (pit attention) of 6 hrs at primary end to enable intensive attention. 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 Washing and cleaning of coaches 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 -do- This is being ensured at other end. -do- Joint certificate issued for newly introduced train by Sr.DME/C&W and Sr.DOM 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 Page 10 of 36 108 of Chg. Manual and Policy circular no. 4 Rake maintenance link has provision of 6 hrs maintenance time for pit attention at primary end. 108 of Chg.Manual Table 1.8 Attention is given for rake cleaning, amenities attention and watering at pit line. Pit occupation chart has been signed by Sr.DME, Sr.DOM & Sr.DEN and approved by DRM 109 of Chg.Manual 109 of Chg.Manual 109 (b)(i) of Chg.Manual Depot is using solution for cleaning as per RDSO specification or as approved by CME. Cleaning solution is provided by contractual agency as per contracts provision. The following solution for cleaning of Jhonson Diversity are being used by depot: 1. PVC floor: Taski Spiral F 11Y – Floor cleaner concentrate 2. LP sheet, Rexene & roof: Taski R7. 3. Toilet cleaner: - Taski R1 Super – Bath room cleaner cum sanitiser concentrate. 4. External painted surface: Taski Spiral F 11Y. Wooden wedges are applied to avoid rolling down of rake and red protection board is applied. Coaching depot – NCC - (Sealdah), E.Rly. April 2012 SN Item 12.3 Clause time rake is under maintenance External cleaning /washing: Check that guidelines as detailed in CAMTECH manual are being followed. 109 (b) of Chg.Manual 12.4 Cleaning of Toilet: Check that guidelines as detailed in CAMTECH manual are being followed. 109 (c) of Chg.Manual 12.5 Internal cleaning of upper class AC and sleeper coaches: Check that guidelines as detailed in CAMTECH manual are being followed. Internal cleaning of GS, SLR: Check that guidelines as detailed in CAMTECH manual are being followed. 109 (d) of Chg.Manual Cleaning of buffers and screw couplings 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. 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 Conditions required for maintenance of 24 coach trains (Railway Board’s letter No.98/M(C)/137/19 Pt.I dt.28.7.99 & 5.5.2000 Infrastructural requirements 24 coach length fully equipped pit line. 109(f) of Chg.Manual High pressure jet cleaning pipeline with plant for cleaning at primary pit line. Mechanized external cleaning is preferable Water hydrants for 24 coach length at en route watering stations with 20 minutes stoppage at nominated stations 110(a)(ii) of Chg.Manual Availability of the prescribed air brake maintenance and testing equipment. 110(a)(iv) of Chg.Manual 12.6 12.7 (i) (ii) 13 13.1 (i) (ii) (iii) (iv) 109(e) of Chg.Manual Observation Coaches of 13153 have been checked during audit on 14.04.12. External cleaning is found satisfactory. Coaches of 13153 have been checked during audit on 14.04.12. Cleaning of toilets in NAC and AC coaches are found satisfactory. Coaches of 13153 have been checked during audit on 14.04.12. Internal cleaning of toilets is found satisfactory. Coaches of 13153 have been checked during audit on 14.04.12. Internal cleaning of GS and SLR is found satisfactory. 109(f)(i) of Chg.Manual This is being ensured. 109(f)(ii) of Chg.Manual This is being ensured. 110 of Chg.Manual 110(a) of Chg.Manual 110(a)(i) of Chg.Manual 110(a)(iii) of Chg.Manual NCC depot has 6 (six) deep pit out of which 3 deep pits are of 24 coach capacity and 03 deep pits are of 22 coach capacity. Cleaning is being done with high pressure jet machine. For en-route watering, adequate time at en-route watering station has not been provided. SDAH Rajdhani (12313/12314) and SDAH Duronto (12259/12260) have only 10 mts stoppage time at MGS for coach watering. Total 10 nos. RTR are available for air brake testing. Air pressure is 10 – 2 7.5 Kg/cm . Compressor of 500 CFM (1 no) and 300 CFM (3 nos) are available in Page 11 of 36 Coaching depot – NCC - (Sealdah), E.Rly. April 2012 SN Item 13.2 Coach Design related requirements Air brake with twin pipe graduated release system 110(b) of Chg.Manual 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 have been provided with enhanced capacity draw gear and screw coupling (75 T capacities). LHB /Duronto coaches are provided with H type CBC. 13.3 Maintenance practices and system related requirements The integrity of the rakes to be maintained. 110(c) of Chg.Manual 110(c)(i) of Chg.Manual Integrity of rake is maintained. Primary maintenance of the rake should be done in one hook without splitting Minimum maintenance time of 6 hours on the pit during primary maintenance 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) Trains leakage rate to be maintained within prescribed limits by using rake test rig. Provision of proportionate brake system on the locomotive in good working order Provision of audio visual alarm system on the locomotive 110(c)(ii) of Chg.Manual This is being ensured 110(c)(iii) of Chg.Manual This is being ensured 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. 110(c)(v) of Chg.Manual This is being ensured. Air brake testing is being done with RTR. 110(c)(vi) of Chg.Manual Air flow measuring valve has been provided in locomotives 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 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 2 nos van RB’s letter no. 95/Sec (spl)/75/1 dtd 30.05.97 Air flow measuring valve has been provided in locomotives. Quarterly and yearly attention as stipulated is provided in-house by depot. DCP type FE’s are provided as under: (i) i) ii) iii) iv) v) vi) vii) 15 Clause AC / SLR – 2 nos each Pantry car – 04 nos. Generator car – 02 nos. 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 Coaching depot – NCC - (Sealdah), E.Rly. April 2012 Similarly, other brake van equipment, which Mechanical Train Examining staff is responsible to supply, should be provided according to the instructions of each Railway. Page 12 of 36 Observation working condition. 111(g)(i) of Chg.Manual SN Item Clause Portable control telephones, portable train lighting equipments, portable fire extinguisher, wooden wedges/skids and stretcher are to be provided. Watering and cleaning of rakes Mechanical department of each railway will nominate the watering and the cleaning stations on the railway. Deficiency Rolling Stock (DRS) for Coaching Stock 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. 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. Coach Maintenance History Card Every coaching depot shall have computers for maintaining the coach maintenance history in a software programme which should be compatible with the programme of the coaching workshop. 16 17 (i) (ii) 18 (i) (ii) 19 19.1 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 Primary/Secondary maintenance 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 Page 13 of 36 Observation sealed. 111(h) of Chg.Manual ASN & MLDT are nominated CTS in ER. Watering station is ASN, MLDT and RPH in ER 111(i) (i) of Chg.Manual This is not being followed. DRS reports are not prepared jointly. 111(5)(b) of Chg.Manual This is not being followed. 111(k)(i) of Chg.Manual 111(k)(iii) of Chg.Manual 113(a) of Chg.Manual Coaching depot is maintaining coach maintenance history in computer (in Access based software) which is accessible to coaching depot officer 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. This is not being followed. This is being followed. The depot is carrying out the following attention at depot: Mail Express trains PM with RTM at other end 13 PM with SM at other end 04 RT attention (other base) 03 RT attention (own base) 03 Passenger trains PM with RTM at other end 08 Total attention 31 Coaching depot – NCC - (Sealdah), E.Rly. April 2012 SN Item 19.2 Coaches shall be washed and cleaned thoroughly from outside and inside as prescribed in clause 109. 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. 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. The following items of under-gear components should, however, be specially examined and attended to:Oil in hydraulic dash pots of Rajdhani and Shatabdi coaches should be checked once in 15 days to detect oil leakage from them through defective seals or through the vent screw. Add/ replenish with specified grade of oil if the oil level is below 40 mm in the tare condition for ensuring better riding comfort. Wheel profiles should be visually examined and gauged in case they appear to be near condemning limits. 113(b) of Chg.Manual Observation This is being followed. 113(c) of Chg.Manual This is being followed. 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. 113 (e) of Chg.Manual This is being followed. 113 (e) (i) of Chg.Manual Oil level in dash pot is checked on monthly basis and oil is filled up on need basis. 113(e)(ii) of Chg.Manual This is being followed. 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) The following coach body components and fittings should be specially checked and attended to Doors should be properly secured with the hinges/pivots and should 113(e)(iii) of Chg.Manual This is being followed. ICF coaches have been provided with BMBC and piston stroke is adjusted to 32 mm by depot during PM. 19.3 19.4 19.5 i) ii) iii) 19.6 i) Page 14 of 36 Clause 113 (f) of Chg.Manual 113(f)(i) of Chg.Manual This is being followed. Coaching depot – NCC - (Sealdah), E.Rly. April 2012 SN Item ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) 20 i. ii. iii. 21 i. ii. Clause Observation not be grazing with floor or door sill plates. Door latches and safety catches 113(f)(ii) of Chg.Manual This is being followed. Door lock handles 113(f)(iii) of Chg.Manual This is being followed. Tower bolts 113(f)(iv) of Chg.Manual This is being followed. Window shutters should neither be tight nor loose Window shutter safety catches 113(f)(v) of Chg.Manual This is being followed. 113(f)(vi) of Chg.Manual This is being followed. Window frame 113(f)(vii) of Chg.Manual This is being followed. Vestibule assemblies of all vestibule coaches should be checked and repaired as necessary. Water pipe connections, flushing valves, cocks and shower roses should not be leaking or choked. 113(f)(viii) of Chg.Manual This is being followed. 113(f)(x) of Chg.Manual This is being followed. Drain grills and drain holes in the bathroom floors and wash basin drainpipes should be cleaned and opened where found choked. Any other deficiency as per Annexure 1.2 should be made good. 113(f)(xi) of Chg.Manual This is being followed. 113(f)(xii) of Chg.Manual This is being followed. 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) Schedule ‘A’ Examination 113(h) of Chg.Manual Depot is maintaining record of PM in DDR. Separate records for Upper body and under gear are maintained. All relevant records are maintained for rake wise during PM of rake. 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. Brake system maintenance Air brake system (bogie mounted) A schedule maintenance as per air brake chapter The specified items of work should be attended during Schedule ‘A’ examination, i.e. monthly examination. 114(b) of Chg.Manual This is being followed. 114(c) of Chg.Manual This is being followed. Record of schedule ‘A’ examination is maintained in printed schedule form. Schedule ‘B’ Examination 115 of Chg.Manual 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. The specified items of work should be attended. 115(a) of Chg.Manual Page 15 of 36 114 of Chg.Manual 115(b) of This is being followed. This is being followed. Record of schedule ‘B’ examination Coaching depot – NCC - (Sealdah), E.Rly. April 2012 SN Item Clause iii. Brake system maintenance Air brake system (Bogie mounted) (i) Same as 'A' schedule iv. Other assembly maintenance Besides brake system other items should be attended as given below: All items of Schedule`A' Chg.Manual Observation is maintained in printed schedule form. This is being followed. This is being followed. 115(b)(i) of Chg.Manual 115(b)(ii) of Chg.Manual Painting of lavatories from inside. 115(b)(iii) of Chg.Manual c. Thorough inspection and repairs of brake gear components. 115(b)(iv) of Chg.Manual This is being followed. This is not being followed. Attention is given on need basis. This is being followed. d. Thorough checking of trough floor, turn unders, etc., from underneath for corrosion. Touching up of painted portion, if faded or soiled. 115(b)(v) of Chg.Manual This is not being followed. 115(b)(vi) of Chg.Manual This is not being followed. Attention is given on need basis. a. b. e. IOH attention 22 22.1 22.2 22.3 22.4 116 of Chg. Manual and Correction slip 5 for coaching maintenance manual issued in 2008 Periodicity of IOH attention: 117(i) of Chg. Manual and correction slip 5 for Coach Periodicity coaching maintenance Category at interval of 12 manual issued in 2008 New coach months in Depot at interval of 9 Rajdhani months in Satabdi (Conv) workshop at interval of 9 Mail / Express months in depot at interval of 9 Passenger months in depot at interval of 12 Other OCVs 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 Coaches are required to be 117(ii) of Chg.Manual detached from the rake and taken and Correction slip 5 for to the sick line or sent to shop for coaching maintenance IOH attention (‘C’ schedule manual issued in 2008 maintenance) Brake system: ‘C’ schedule 117(a)(i) of Chg.Manual maintenance (IOH) as per para 426 of air brake chapter. Thoroughly clean Dirt collector filter in kerosene or replace on condition basis. Page 16 of 36 117(a)(vii) of Chg.Manual Existing sick line at NCC depot has no crane facilities. IOH attention is given at KPA /shop and Kolkata terminal (Chitpur) depot. LHB coaches and AC coaches are attended at LLH shop. Newly built coaches (ICF design) are attended at Depot as per Board’s guidelines. During 2011, status of IOH attention for ICF design coach is as under: IOH attention at KPA shop IOH attention at LLH shop IOH attention of newly built coaches IOH attention of pass. coaches 190 76 88 8 Overdue IOH coaches: 19 For newly built coaches, guidelines are followed. For IOH attention, detached from rake. coaches RB’s are This is being followed. Attended at depot after attention of bogie at shop. Attended at depot during IOH attention of coaches at depot. Coaching depot – NCC - (Sealdah), E.Rly. April 2012 SN Item 22.5 Other assemblies maintenance All items of Schedule `B' 117(a)(i) of Chg.Manual 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”. Touching up damaged paint of coaches on outside as well as inside. Polishing of the polished surfaces. 117(a)(ii) of Chg.Manual 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. Thorough cleaning and removal of dust, rust, dirt, etc., accumulated at the pillars through the turn under holes, with coir brush and compressed air. Thorough examination and repairs of upholstery, cushions, curtains, etc. Thorough checking and full repairs of all window shutters, safety catches, safety latches, staples and hasps of compartment, lavatory, Thorough checking and repairs of UIC vestibules, their rubber flanges metal frames, doors, fall plate, locking gear, etc., for ease of operation and safety . Thorough checking and repairs of all cracks and worn out portions of flooring of the compartments. 117(a)(v) of Chg.Manual 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 22.7 22.8 22.9 22.10 22.11 22.12 22.13 22.14 22.15 Page 17 of 36 Clause Observation Coaches turned out from shop are not attended. At shop, only bogies are overhauled and attention to air brake system and upper body is not given. Attended at depot during IOH attention of coaches at depot. This is being followed. Bogies are overhauled during IOH attention at shop. In addition, shop is supplying bogies to depot for IOH attention. 117(a)(iii) of Chg.Manual Attended at depot during attention of coaches at depot. 117(a)(iv) of Chg.Manual Depot is carrying out buffing operation to polish SS wash basin and toilets seat. Attended at shop during overhauling of bogie. IOH 117(a)(vi) of Chg.Manual This is not being followed. 117(a)(vii) of Chg.Manual This is being followed. 117(a)(viii) of Chg.Manual This is being followed. 117(a)(ix) of Chg.Manual This is being followed. 117(a)(x) of Chg.Manual This is not being followed. 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. One coach in sick line checked and found that coach ER 10107 (built RCF & POH/LLH- 16.02.12) is not provided with elongated holes of 215x127 mm size. Coaching depot – NCC - (Sealdah), E.Rly. April 2012 SN Item 22.16 i) II). III) 22.17 22.18 Clause already provided in the turn under. Special attention should be taken for the following: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. 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. 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. For maintenance of coaches of Rajdhani/ Shatabdi Express Rakes, the instructions given in RDSO Technical Pamphlet No. C7807 should be followed. The IOH of Rajdhani/Shatabdi high speed coaches should be carried out in workshops Observation 117(e) of Chg.Manual 117(e)(i) of Chg.Manual This is not being followed. 117(e)(ii) of Chg.Manual This is being followed. 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 for under-gear attention only. Record for upper body attention is not maintained. For IOH attention at shop, no record for attention of under-gear and upper-body is available. LHB coaches have been provided in Rajdhani / Duronto Express (SDAH – NDLS). ICF coaches have been provided in Puri Duronto. 118 (b) of Chg.Manual 118(c) of Chg.Manual IOH attentions of Rajdhani / Duronto rakes (LHB coaches) are carried out in LLH shop. Board’s letter No.2009/M(C)/165/6 dt.17.12.2009. C&W department/Sealdah has taken charge of linen management form Commercial Department on 01.08.11. Board’s letter No.2009/M(C)/165/6 dt.4.1.2010 Stock verification is carried out on a quarterly basis. Minimum 5 % of new linen checked by SSE/C&W as per guidelines. Linen management 23 i. ii.(a) ii.(b) ii.(c) 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 Stock verification of linen should be carried out on a quarterly basis 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. 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 / Page 18 of 36 This being ensured. Penalties as applicable are deducted from bill and payment is made after recovery of all penalties / dues. Coaching depot – NCC - (Sealdah), E.Rly. April 2012 SN Item Clause Observation dues ii.(d) ii.(e) ii.(f) Enough buffer stock of linen to last for 2 to 3 days is available 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 Committee nominated by DRM for linen condemnation on condition basis iii. Specified frequency of washing/dry cleaning of blankets and other linen items is adhered to 23.1 Passenger complaint on account of linen is analysed and corrective & preventive action is taken 23.2 Feedback on linen quality is obtained through coach attendant as per RB’s guidelines 24. i. ii. iii. Stock of 2 days washed linen is available in depot. Linen items are condemned as per recommended life of linen or on condition basis. A committee consisting of CDO, ACM & ADFM has been nominated for linen condemnation. Blankets are dry cleaned at 3 month interval against recommended washing cycle of every month till Dec’11. Depot has started dry cleaning of blanket on monthly basis from Jan’12 onward. Passenger complaints are analysed and corrective and preventive action is taken. After C&W department has taken charge of linen management on 01.08.12. Depot has adopted a feedback system for quality of linen from coach attendant. Feedback for each coach in a rake is submitted in standard format by CA. Feedbacks collected through CA is computerised and assessed by Depot officer and supervisor for taking corrective and preventive action. Pest / Rodent Control 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 All reserved (both AC and NonAC) covered under contract, unreserved coaches may also be covered as per requirement of Railways 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, Page 19 of 36 Board’s letter No.2010(M)/C/141/7 Vol.IV dt.21.12.2010 Pest control is awarded to CP pest control. Depot has yet to award contract as per model contract for pest control issued by Railway Board. Tender is under process. Performance of pest control agency to carry out pest control is not satisfactory. Depot has taken some additional initiative on its own for pest & rodent control management and passenger complaint on account pest / rodent reduced to 3 complaints from Sep’11 to Mar’12 against 22 complaints from Apr’11 to Aug’11. All reserved coaches (both AC and Non AC) are covered for pest control. The following frequency is adopted for pest control treatment: AC coach – Weekly Non AC coach – Fortnightly. Pantry car (AC) – Weekly. Coaching depot – NCC - (Sealdah), E.Rly. April 2012 SN Item Clause Unreserved Non-AC coaches : Bimonthly Maximum tolerance +7 days, on account of operational exigencies, disturbance of rake links, etc. Chemicals to be used (with brand names), concentration, dose specified iv. 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. vi. Personnel trained by certified training institutes deputed for pest/rodent control vii. Fumigation/mist treatment carried out whenever coaches detached for IOH/POH. Pest/rodent control carried out before inducting the coach in service after IOH/POH viii. In order to prevent cross infestation, contractor may make effort to treat all AC and all NonAC coaches of a particular rake together Stickers indication date of pest control and next due date provided in doorway/toilet area 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 Broad methodology for measuring the level of infestation of cockroaches and rodents and expected reduction over time is in place Passenger complaints on account of pest are analysed and corrective action is taken. ix. x. xi. 24.1 Page 20 of 36 Observation Pantry Car (NAC) – Weekly For fogging – King fog (Mfg – Bayer) For spraying – Flyco (Propoxer), Baytex (Fenthoin), K – obiol (Deltamethrin) of M/s Bayer, Deltajet (Deltamethrin) of M/s Heranda. Depot has adopted effective rodent control measure. Garbage from all coaches including pantry car are collected at platform and disposed. This has resulted in minimum accumulation of garbage at depot during PM of rakes. In addition, all pantry cars are unloaded at platform for effective cleaning. Regular rodent control measure is taken inside the depot. Rodent control measure has been adopted en-route also by providing glue board and specially designed rat traps in coaches. However, rodent control measure has not been taken by Sealdah Division at platform area. Personnel for pest & rodent control have not been trained by certified training institute. Pest control is not being done in coaches detached for IOH/POH attention. Pest/rodent control is carried out in off IOH/POH coaches before inducting the coach in service. All reserved coaches (AC and NAC) of a rake are given pest control treatment together. This is being ensured. Pantry cars are detached from rake once in a month to facilitate complete vacation and intensive cleaning for thorough pest / rodent control treatment As per RB’s guidelines, pest infestation is measured by providing bait (CMT). Record of pest and rodent infestation is maintained. This is being ensured. Passenger complaints are analysed for corrective and preventive action. In addition regular feedback is taken Coaching depot – NCC - (Sealdah), E.Rly. April 2012 SN Item 25. Passenger amenities provided in various types of coaches as specified Board’s letter No.2006/M(C)/141/26 dt.21.12.2006. 26. Infrastructure facilities – Standard integrated modular pit line have unified maintenance. 27 Examination and repair practice in carriage maintenance depot for wheel sets and roller bearing Wheel and axle Appendix ‘E’ of Coaching manual CAMTECH report No.CAMTECH/M/99/Infrawashing line/1.1 Para 1009 of Chg manual 27.1 i) ii) iii) a) b) c) d) e) iv) Clause Para 1009 a of Chg manual Observation for pest / rodent infestation through coach attendant. Officer/ supervisors have also been deployed to collect feedback of pest / rodent infestation in coaches. 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). NCC deep pits design is slightly different from CAMTECH design deep pits. Catwalk width is less and side of pit is at higher level. Total 81 wheel sets attended in 2011 -12 due to canted (12 cases), grease oozing (15 cases), Grazing with wheel (9 cases), warm and hot (3 cases) and other (cover, axle box wing etc – 11cases. Wheel profile should be checked with Tyre defect gauge to ensure the profile dimensions are within the permissible limits. 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) 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: Shattered Rim This is being ensured. Spread Rim This is being ensured. Shelled Tread This is being ensured. Thermal Cracks This is being ensured. Heat checks This is being ensured. The defective wheel should be sent This is being ensured. Page 21 of 36 This is being ensured. Supervisors are aware of various wheel defects. However, CMI –K003 guidelines have not been displayed on shop floor and displayed in sick line only. This is being ensured. Coaching depot – NCC - (Sealdah), E.Rly. April 2012 SN Item Clause to workshop for repairs after entering in the maintenance card details of the work order and date of dispatch to workshop. No repairs, except wheel profiling of wheel sets are permitted to be done in the maintenance depot. v) 27.2 i) ii) 27.2. 1 27.3 i) ii) 27.4 Roller Bearing Axle Boxes Observation This is being ensured. Para 1009 b of Chg manual 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. Care should be taken not to keep a coach fitted with roller bearing stationary for a long time. Coaches grounded for a long time should be shunted up and down at regular intervals. Coaches fitted with roller bearing should be checked to ensure that :i) No wash basin drain hole / discharge pipe is directly above the axle box ii) The front and rear covers of the axle boxes are not damaged, cracked or loose iii) Clearance between axle box and wheel is such that the axle box does not bind against the wheel. iv) Brake gear is properly adjusted to avoid possibility of brake binding This is being ensured. 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. Axle box temperature measurement by non contact type temperature measuring instrument during rolling in examination: This is being ensured. Temperature to be checked at axle box top (crown) at front face of axle 0 If temperature is found above 80 C, the affected coach will be detached. Minimum permissible wheel Page 22 of 36 There is no en-route detachment of base depot coaches on account of roller bearing failure in 2011 – 12. This is being ensured. This is being ensured. This is being ensured. This is being ensured. Total 15 wheel sets have been changed in 2011 -12 on account of grease oozing out. 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. 8 nos non contact type temperature measuring instrument are available at Sealdah PF. This is being ensured. This is being ensured. RB letter no. 92/M Coaching depot – NCC - (Sealdah), E.Rly. April 2012 SN Item Clause diameter in ICH design BG coaches. Shop issue size of wheel set should be 837 mm i) This is being ensured. Shop last issue size in off POH coaches is 837 mm This is being ensured. Last shop issue size in off POH coach is 837 mm. Shop issue loose wheel sets upto 830 mm and wheel condemning limit in open line is 825 mm. ii) Condemning diameter of the wheel in service, measured at a distance of 66.5 mm from the outer face of the rim shall be 825 mm. 28 Attention brake block hangers on ICF coaches – to avoid failures The new brake block hanger should be procured as per revised spec C – 9808 Rev 2 and drg no. SK – 93286 Alt 5 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 Other items: Carriage Dte/RDSO letter no. MC /ICF/B/D dtd 03.07.09 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 Fire retardant items are provided in coaches as per RDSO specification. FAC amenities are provided as per guidelines circulated vide DG/Carrg/RDSO’s letter no. MC/CB/AC/BG dtd 28.04.10 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 Maintenance of Duronto express: Pattern of maintenance for Duronto train as being followed for Rajdhani trains with pit examination at both end should also be follwed. RDSO spec and STR 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 RB letter no. 2009/M (C)/141/2 dtd 25.08.09 28.1 28.2 29 29.1 29.2 29.3 29.4 29.5 i) ii) Page 23 of 36 Observation (C)/137/2 Vol V dtd 25.1.11 This is being ensured. This is being ensured. There is no hanger breakage case in 2011 – 12. Shop is changing air brake hose pipe in every POH. Open line has no MC for new hose pipe. Serviceable hose pipe from shop supplied to division. This is being ensured. This is being ensured. RB letter no. 2004 / M (C)/165/16 dtd 29.03.05 Snack table, magazine holders on partition wall and bottle /tumbler holders are not provided in all sleeper coaches. RB letter no. 2009/M (C)/141/2 dtd 25.08.09 This is being ensured for SDAH NDLS Duronto Express (with LHB coaches). SDAH – Puri Duronto is given PM with RT attention at other end. This is being ensured. Super checking report of officer is not available. Coaching depot – NCC - (Sealdah), E.Rly. April 2012 SN Item iii) iv) 29.6 29.7 i) ii) Clause super checked at the level of officers. 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. 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. Attention of air springs Procedure for rolling – in examination: As train passes the nominated point, C&W staff should watch out vigilantly loose / hanging / broken under gear parts of the coaches special attention should be paid to air springs in case of coaches provided with air springs at secondary suspension stage. It should be ensured all the air springs are in inflated condition by noting that the levelling valve lever is in horizontal position. In case it is not feasible to inflate the air springs of any particular coach, these should be isolated by air spring isolating cock and speed of train should be reduced to 60 Kmph or the coach should be detached. Analysis of sick marking and en-route coach detachment Whether primary coach detachment is analysed and corrective & preventive action taken. Details of primary detachment for last 3 years to be collected. Whether secondary detachment is being analysed and corrective & preventive action taken. Details of secondary detachment for last 3 years to be collected. Page 24 of 36 Observation RB letter no. 2009/M (C)/141/2 dtd 26.07.11 Short distance Duronto with AC/Non AC chair car is not maintained at depot. RCF’s letter no. MD 22.151 dtd 09.02.10 This is being ensured. 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 DEMU coaches (total holding - 8 coaches) are fitted with air spring. Attention as recommended is given. Primary detachment from coaches are being analysed by depot for taking CA & PA. Primary detachment has reduced to 7.03 /100 coach holding during 2011 – 12 as compared to 8.53/100 coach holding during 2010 – 11. Major contribution is tank leaky (16.03%), Brake cylinder (10.7%), Main/Lugg/Lav door (10.03%), Wheel sets (9.34%), Bk rigging (6.9%), draw & buffing gear (5.99%) Secondary detachment from coaches are being analysed by depot for taking CA & PA. Coaching depot – NCC - (Sealdah), E.Rly. April 2012 SN Item Clause Observation Summary of secondary detachment during last three years is as under: Yr 2009 – 10 2010 – 11 2011 – 12 iii) Whether en-route coach detachment is investigated and corrective & preventive action taken. Details of en-route coach detachment for last 3 years to be collected with investigation report. 29.8 Facilities for pit line and sick line attention Facilities available as per CAMTECH guidelines as detailed in annexure – I to be observed. i) 30 30.1 i) ii) iii) iv) v) LHB 6 ICF 18 Total 24 14 43 57 7 43 50 Secondary detachment is mainly on account of spring breakage, dash pot safety strap broken/missing. There is no en-route detachment of coaches in 2011 -12. Summary of en-route detachment during last three year is as under: Yr LHB ICF Total 2009 – 0 2 2 10 2010 – 1 0 1 11 2011 – 0 0 0 12 CAMTECH Maintenance Manual for BG Coaches of ICF design, st 1 correction slip– CAMTECH/2002/M/C/ CMM/1.0/CS-01(07.2006) Status has been indicated in Annexure - I Passenger satisfaction OBHS & escorting of trains Whether depot has provision of OBHS as per RB policy guidelines. Nos of Mail Express train in which escorting staff have been provided with cleaning staff by depot. Nos of Mail / Express trains in which OBHS have been provided. Nos of Mail/ Express train in which no staff from depot and OBHS through contract have been provided. Average PSI for OBHS implemented rakes. Whether systems to cross verify PSI in OBHS provided train exist. Page 25 of 36 OBHS through outsourcing as per RB’s guidelines has been provided in 7 important Mail/Express trains. In LHB Rajdhani (SDAH – NDLS) and Duronto (SDAH – NDLS), OBHS through outsourcing have been provided. In addition C&W maintenance staffs are escorting as per guidelines. Escorting staffs for maintenance and cleaning have been provided by depot in SDAH - Puri Duronto. OBHS have been provided in 8 trains (7 through outsourcing and one train by depot) All major Mail/Express trains have been provided OBHS through contract and escorting by depot. Av PSI is 97%. System exists to verify PSI by depot and deduction has been made accordingly. Coaching depot – NCC - (Sealdah), E.Rly. April 2012 SN Item 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. Clause 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. 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. 30.5 Whether depot has facility for upholstery and carpet cleaning either through in-house or through contract. Efficacy of cleaning to be observed. 30.6 Whether curtains are cleaned at prescribed interval of 15 days as per RB guidelines Whether blankets are cleaned at one month interval as per RB guidelines 30.7 30.8 i) a) b) c) d) e) Compliance of CRB letter to GM for sustainable image makeover of the Railways: Cleanliness of coaches: Ensure high standards of cleanliness in the coaching maintenance depot particularly in the washing line area. Action in respect of implementation of systems for collection bagging and disposal of leftover food from pantry cars and coaches. Sustainable garbage collection and disposal system Functional and efficient drainage to avoid water logging and dirt collection Periodic fumigation of coaches and high standards of cleanliness Page 26 of 36 Observation Depot has a system to get feedback of cleanliness, linen quality and pest infestation of Mail/Express trains. Officers and supervisors have also been deployed for on-board inspection to get the feedback of cleanliness, linen quality and pest infestation. Action is taken on the basis of passenger complaint. Passenger complaints for last three years are as under: Yr Pest/ rode nt 60 Line n Other s Tot al 100 30 90 11 1125 3 27 55 12 Depot has awarded contract for mechanised cleaning of coaches and equipments are provided by agency. Cleaning activities of coaches have been outsourced. FAC (7 coaches) and composite AC (7 coaches) are provided with upholstery. Carpets have been removed from coaches. Contract to carry out upholstery cleaning expired and presently cleaning activity is being carried out by cleaning gang engaged for cleaning Curtains are cleaned at one month interval. Blankets were cleaned at two months interval. Depot has started dry cleaning of blanket at one month interval form Apr’12 onward. CRB DO no. 2011/ER/6018 dtd 28.07.11 Cleaning standard is satisfactory. Depot has adopted collection and disposal of leftover food and refuses from coaches after arrival of train at station. The system is available. Drainage is adequate. Periodic pest control treatment is Coaching depot – NCC - (Sealdah), E.Rly. April 2012 SN Item Clause in washing lines f) Monitoring the functioning OBHS and CTS scheme. 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. Quality of linen supplied on trains: 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. ii) a) of b) Commissioning of mechanised laundries at critical locations dealing with large quantity of linens c) System of packaging, storage and servicing of the linen to the passenger must be streamlined. 31 31.1 Observation being done through fogging machine. Cleanliness is being ensured in washing area. Functioning of OBHS is monitored. Officers and supervisors are carrying out on-board inspection to monitor performance of OBHS. Officers in SAG have been nominated at Zonal level under “OYTS”. Reports of on-board inspection are available with depot and corrective actions are taken on the basis of inspection note. Linens are cleaned through mechanised laundry. Depot has installed one mechanised laundry which cater requirement of 3500 packets per day. Depot has total requirements of 10,000 packets per day. Balance quality is washed through outsourcing in mechanised laundry. 25% extra quantity is supplied in each coach. Regular condemnation is being done on condition / age basis and replenished with new linen. One mechanised laundry has been commissioned at depot and in regular use since May’11. Total 3500 packets are washed in this laundry. Packaging and storage is adequate. Servicing to linen is being done by coach attendant of electrical department except for SDAH –Puri Duronto. CA has been provided by C&W department in SDAH –Puri Duronto through out-sourcing. LHB coach attention: Periodicity of periodic overhauls RB’s letter no. 95 /M (C)/ (POH) in designated workshops is 141 (LHB) dtd 22.08.06 being followed. Schedule Periodicity IOH (Shop Sch I) 18 months / 5 lakh Km POH (Shop Sch 3 yrs/ 10 lakh Km II) POH (Shop Sch 6 yrs / 20 Lakh Km III) Page 27 of 36 Depot has total holding of 111 LHB coaches. 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. D3 schedule is not adequate as coach is not detached from rake for Coaching depot – NCC - (Sealdah), E.Rly. April 2012 SN Item Clause 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 Observation attention in sick-line. Depot has contract for disc brake (including air brake) attention in LHB coaches for KB makes brake system. However, contract for Faively Transport make disc brake system is not available. Depot is carrying out maintenance attention of FTIL make phonic wheel / speed sensor thorugh in-house. Population of KB and FT make disc brake system is as under KB make: 55 FTIL make: : 56 Attention for phonic wheel and speed sensor is given as per recommended frequency. Earthing devic 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. All CDTS are in working condition. Primary dampers in some coaches are defective which resulted in loosing of mounting bolts of control arm. Mounting bolt is tightened regularly during PM. Depot is not getting dampers against indent placed on RCF. Receipt of dampers by depot during 2011 – 12 is as under: Primary dampers: 18 Secondary dampers: 16 Lateral dampers: 18 Yaw dampers: 08 31.3 i) ii) Wheel sets and CTRB attention at depot: 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 Wheel profile should be checked with Tyre defect gauge to ensure the profile dimensions are within the permissible limits. Coaches with wheels having thickness and profile worn below condemning limit should not be allowed to continue in service and the coach should be marked sick for change of wheels in the sick lines. Page 28 of 36 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 displayed in sick line only. Para 1009 a (i) of chg manual This is being followed. Coaching depot – NCC - (Sealdah), E.Rly. April 2012 SN Item 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) 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. iv) Last shop issue size (865 mm) and condemnation limit for wheel sets (845 MM) as stipulated is being followed. 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. v) vii) viii) ix) x) Clause Depot should not permit wheel sets with flaking in service. Adequate spare wheel sets are available in depot. 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. Grease oozing out is checked during attention at depot and corrective action is taken accordingly. Page 29 of 36 Para 1009 a (ii) of chg manual Carriage Dte/RDSO letter no. MC /AB dtd 21.08.09 Observation This is being followed. Rolling–in examination is being carried out at SDAH station. Axle box temperature is measured with noncontact type temperature measuring equipment. Corrective action is taken for wheel sets with high temperature. In addition, depot has provided temperature strip on axle boxes to measure temperature on running. Corrective action is taken on the basis of high temperature recorded. This is being followed. Traceability of wheel sets is ensured. Attention as stipulated is given for attention of CTRB at an interval of 1.2 Million Km. Wheel sets are cannibalised during maintenance and wheel sets sent to shop when due for CTRB attention (at 3 years interval). As per RB guidelines, coaching axle need to be given UST at one year interval. Presently attention is given to axle for UST when wheel sets touch the workshop. IOH attention is given at 18 months interval. It is also observed that no attention is given for UST of axle at depot and wheel sets with life of more than 2 years are in service without UST of axle. Wheel sets with flake is not permitted in service. This is being ensured. Details provided to shop. 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. Coaching depot – NCC - (Sealdah), E.Rly. April 2012 SN Item xi) Drain holes of control arm should be regularly cleaned to prevent its choking. Checking of mounting bolts of control arm is being done during primary maintenance. xii) 31.4 i) ii) iii) iv) 31.5 31.6 Clause Phonic wheel/Speed censor 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. 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. 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. Speed sensors’ cables should be properly connected and should be without any loose strands. Dump Valve Proper Dump Valve connection and ensuring that no dump valve leaks during brake application. Earthing Device 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. Most of the earthing devices with connecting wires/cables were missing. Junction box in broken/damaged condition. Page 30 of 36 Observation 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. This is being ensured.. This is being ensured. Primary dampers in some coaches are defective which resulted in loosing of mounting bolts of control arm. Mounting bolt is tightened regularly during PM. Depot is not getting dampers against indent placed on RCF. OEM guidelines This is being ensured. This is being ensured. This is being ensured. This is being ensured. OEM guidelines This is being ensured. OEM guidelines All earthing devices are working. Earthing devices are maintained through AMC on OEM. Earthing devices wire are available. with connecting Junction box is in good condition. Coaching depot – NCC - (Sealdah), E.Rly. April 2012 SN Item 31.7 i) ii) Clause Disc brake attention: Brake pads are renewed on condition basis and adequate spare is available at depot Whether regular attention of brake calliper is being ensured. Brake pads are renewed on condition basis. iii) Whether regular attention is being given to disc brake system through AMC or in-house attention. 31.8 Whether guidelines circulated by RDSO for CBC equipped coaches are being followed. Carrg Dte/RDSO letter no. MC/BLB/CBC dtd 22.05.08 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 Page 31 of 36 Observation OEM guidelines Brake callipers of KB makes are attended through contract. Brake callipers of FTIL makes are not attended as AMC has not been awarded on FTIL after AMC expired in Aug’11. AMC is available for KB make disc brake system. AMC has not been awarded on FTIL after AMC expired in Aug’11 and in-house attention is given. Depot is not aware of Guidelines issued by RDSO. However, at present coaches sent to and received from platform with full brake in working to avoid rolling of LHB rake. 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 Coaching depot – NCC - (Sealdah), E.Rly. April 2012 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 Minor Depot Medium Depot No. of coaches based Below 100 100 to 250 Major Depot Above 250 NCC depot/Sealdah is major depot as coach holding is 794. Availability of Machinery and Plant Minor Medium Major Depot Depot Depot Description Observation U/floor wheel lath Whiting jacks (5 Nos.) - 1 set 1 1 set EOT crane 20T - - 1 Coach Shunter - 1 2 Welding Plant Gas Cutting Equipment Vacuum Exhauster 1 1 1 2 2 2 4 2 2 Air Compressor 30 cfm 1 2 2 - 1 1 Not required 1 1 1 2 1 1 - 1 1 1 1 1 4 1 1 1 1 - 1 2 1 1 1 1 2 1 01 OH hoist (5T) – 2 nos 03 nos 02 nos 01 no 03 nos 08 nos Not available Not available Not required. 01 01 Not required. 02 nos Not available Portable Vacuum Testing Equipment Portable Air Compressor 2T Tram beam hoist Sewing machine Truck 10T Light Coml. Vehicle Fork lift truck Lister truck Car Washer Portable Trolley Light Cotton waste soaking plant Wood cutting saw machine Hand shearing machine Portable Furnace Centre Lath Bogie Manipulator Page 32 of 36 1 1 1 2 1 1 Under construction 12 nos 25 T carne received. Shed is under construction. Available under traffic department. 18 sets 03 sets Not required. 300 CFM – 03 nos. 500 CFM – 1 no. Coaching depot – NCC - (Sealdah), E.Rly. April 2012 Minor Medium Major Depot Depot Depot Description Ultrasonic Testing Apparatus 1 1 Tool post Grinder 1 Vacuum Cleaner 1 2 Pressure Jet Cleaner 1 2 Tools a. Pneumatic Hand Tools i. Grinder 1 1 ii. Drill 1 1 iii. Chipper / Buster 1 iv. Riveter b. Electric Power Tools i. Pop Riveting Gun 1 ii. Drill 1 iii. Bolt Tightner c. Hand Tools As required d. Test Bench i. Water Tank Test Rig 1 ii. D.A. Valve Test Bench 1 iii. Vac. Cyl. Test Bench 1 iv. vi. Slack Adjuster Test Bench Observation 1 Not available 1 3 4 Pedestal grinder – 01 Outsourced Outsourced 2 2 2 1 02 nos 02 nos Nil Not required. 1 1 1 06 nos 06 nos 04 nos Available 1 1 1 Not available Not required. Not required. - 1 1 Not required. v. DV Test Bench Air brake single coach test rig e. Office Equipment i. Computer system 1 ii. Plain Paper Copier 1 iii. Telefax 1 1 1 1 DV testing done at shop. RTR – 10 nos SCTR – 02 nos 1 1 1 1 2 1 Page 33 of 36 Coaching depot – NCC - (Sealdah), E.Rly. 10 02 01 April 2012 Annexure - II Emergency materials required for platform (C&W) office Sl. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Items Screw Coupling complete ( 75 t ) Draw Hook ( ICF- Enhanced capacity) Draft cotter with 'U' pins Draft link complete Equalizing Stay rod with pins ( Non-modif. & Modif.) Anchor link with securing studs Truss Bar Hanger with Pins & Cotters Bolster suspension Link (Stirrup Link) with Pins & Stones Axle Box Face Cover (ICF) with securing nuts & Pins 'O' Ring Grease Servogen Adaptor (BF+FP) for by-passing Angle cock Dummy Flange (A/B) M.U. washer Teflon Tape Portable Air Pressure Gauge Pressure Gauge BP & FP BP & FP Air hose Guard Emergency Application Valve Wooden Plug (various sizes) Wooden wedge G.I. wire Buffer bolts (20x120 mm.) Push cock 2 nos. 4 kgs. 2 sets 2 nos. 2 nos. 10 nos. 1 no. 1 no. 2 each 2 each 2 nos. 10 nos. 4 nos. Adequ. Qt. 8 nos. 5 nos. Spl. Jack for changing Eq/Stay rod 1no. Slide wrench, Pipe wrench-24'' 2 nos Hydraulic Jacks 2 sets 27 28 Page 34 of 36 Required 1 no. 1no. 1no. 2 sets 1 set each 1 set 2 sets 2 sets 2 sets Coaching depot – NCC - (Sealdah), E.Rly. Observation Available Available Available Available Available Available Available Available Available Available Available Available Available Available Available Available Available Available Available Available Available Available Available Available Available Available with Bk down gang at PF Available Available with Bk down gang at PF April 2012 Annexure – III Details regarding coaching depot Depot name and division: 1. Coach Holding Mail/Expresses coaches with conventional coupling Mail/Expresses coaches with CBC coupling Rajdhani/Shatabdi coaches (conv) LHB coaches (Rajdhani/Duronto) Shatabdi Coaches (conv) Shatabdi coaches (LHB) Passenger coaches DEMU’s Grand Total 590 NIL NIL 111 NIL NIL 85 8 794 2. Maintenance attention of at depot Mail Express trains PM with RTM at other end PM with SM at other end RT attention (other base) RT attention (own base) Passenger trains PM with RTM at other end Total attention 13 04 03 03 08 31 3. Pit line attention 24 coach pit with catwalk and high pressure water jet facility/watering facility at per CAMTECH’s guidelines 24 coach pit facility with catwalk and washing apron Less than 24 coach pit facility with catwalk and washing apron 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 Compressed air with reservoir and dryer/moisture trap facility with test rig (RTR) air Facility for welding at Yard attention Night maintenance facility with overhead/pit light as per CAMTECH’s guidelines NIL 03 nos 03 nos Existing 02 nos stabling lines of depot is being converted to deep pit with catwalk and washing apron. Depot is using stabling lines of Kolkata Goods and New stock siding for stabling of rakes. Stabling lines with round trip attention is not available. 4 nos compressors (300 CFM – 3 nos. and 500 CFM – 1 no.) are available with air dryer facility. Facility for welding at Yard attention is available. Deep pit lights are not working. Tube Lights are provided under catwalk. Minor lamps are used for pit attention. Portal lights have not been provided. Overhead lights have been provided t different location for general illumination 4. Sick line facility Coach lifting facility with overhead crane NIL Coach lifting facility with JMP jack/hydraulic jack 12 nos. Total coach accommodation  With pit attention 4 coach Page 35 of 36 Coaching depot – NCC - (Sealdah), E.Rly. April 2012  Without pit attention Facility for compressed air with test rig (SCTR) Availability of hydrant water for overhead tank attention Welding facility 6 coach 02 nos. Water hydrant is available but testing facility to carry out hydraulic testing of repaired water tank is not available. Available 5. Facility for rolling-in/rolling-out examination with adequate lighting arrangement (for attention during night) as per CAMTECH’s guidelines: Deep pit lights are not working. Tube Lights are provided under catwalk. Minor lamps are used for pit attention. Portal lights have not been provided. Overhead lights have been provided t different location for general illumination. 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 For cleaning activity For under-gear attention For sick-line activity For ancillary work Requirement as per Yard stick (bens marking norm) 100 % outsourced 587 156 147 Availability 533 148 212 Shortfall /Excess 54 8 65 7. Training status of supervisor and staff – Overdue supervisor - 34 as Post of STC/KPA is vacant. Training for supervisory staff is not given at present Artisan staff – No overdue schedule. Training of artisan staff is done at divisional training school. 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. Store has not adequate space due to which stacking is not adequate. FIFO is not applied. 9. Availability of coaches as per rake link with maintenance spare: Against requirement of 701 coaches, total available stock is 794. (Maintenance spare as per yard stick is available). 10. Bottlenecks / limitations of system / depot:  Single neck for shunting operation due to which detachment and attachment of coach in rake takes much longer time. Other end of pit line has dead end.  Catwalk and pits are not as per CAMTECH design. Total 6 deep pits were constructed when CAMTECH design has not been finalised. 11. Safety performance record:  There is no derailment / accident on C&W account.  There is no en-route detachment of coach. 12. Performance of critical spare:  Dampers fitted in LHB caches become defective due to oil leakage.  Rubber Bush fitted in damper cracked / perished during service. Page 36 of 36 Coaching depot – NCC - (Sealdah), E.Rly. April 2012