Quality Audit report Of Coaching Depot Wadibander, C Rly Report no. 13/2012 APRIL 2012 (Audit is done by CRSE, WR) Co-ordinated by Quality Assurance (Mechanical ) Directorate Research Designs & Standards Organisation Manak Nagar, Lucknow - 2260511.0 14 12 13 2.0 24 2.2 23 24 25 3.0 3.1 3.2 3.3 Quality audit Report of Wadibunder Coaching depot, Central Railway Introduction ‘As per Railway Board’s directives vide Letter No. 2012/M (Wy/814/5 dated 20.03,2012, Quality audit of coaching depot /workshops were to be done by nominated railways on the neighbouring railways. Accordingly QA of Wadibunder Coaching Depot has been done by WR. Audit Team- — Shri R S Sexena, CRSEIWR Date(s) of audit- 03.04.2012 & 07.04.2012 Escorting Officials - Shri Saket Mishra, Sr DME/Chg/BDVT, Shri Sandeep Verma, AME, Shri Ashok Nagpure Strengths Infrastructure for maintenance at Wadibunder coaching depot is very good. The maintenance lines are clean and catwalks are wide permitting smooth movement of men and material. The ease with which mechanized cleaning apparatus can be deployed promotes adoption of mechanized cleaning by staff. Adequate illumination is available for night maintenance of rakes. The depot was the first to install a mechanized laundry over IR and prides itself as a pioneer in the field. The recognition received in the process has stayed in the form of high morale of the staff. Proximity to major workshop (MTN), Headquarter (CSTM) and stores depot have resulted in better availability of material WEAKNESSES The depot's system of documenting the work done is inadequate. There are a large number of maintenance practices for which evidence of satisfactory compliance is not backed by objective. Lack of documentation would lead to no analysis of failures & further corrective & preventive action. The traceability of subassembly in the depot is inadequate. Certain responsibilities/ information are shared between 4-5 depots which dilutes the responsibilty Page 1 of 27 Coaching depot - Wadibander, C.Rly. April 20123.4 3.5 3.6 3.7 38 3.9 3.10 The depot is following obsolete MIS and the data is also not updated promptly. The information is scattered between the OH shed, maintenance shed and laundry. A single repository of information is not available. The pit line attention for TN 12141 (CSTM-Rajendra Nagar Express) & 11093 (Mahanagari Express) is less than the stipulated six hours. This is mainly because of late placement. TN 12859 (Geetanjali Express ) has been given only 5 hours pit line occupation time which needs to be corrected. Joint check of rakes upon arrival with electrical and RPF staff is not being done. For condemnation of linen on condition basis nomination of Committee has not been done yet. For new linen 5% checks at the level of SSE (Mech) are not being done. Evidence for quantity of chemicals used for Mechanised cleaning/ OBHS was not available, in terms of per coach or per rake basis. Page 2 of 27 Coaching depot - Wadibunder, C.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) S.No. Tem Clause ‘Observation 1. | Periodicty of periodic overhauls (POR) in | 103 of Chg Manual | Coach holding Bare 391 Total 445 designated werkshonsis boing folowed. | Talo .1_ and | Overdue POH - None as on correction "slip issued in 2008 9804-2012 RB letter no. 2007/M C cyiait ata 26.08.08 7% | Maintenance schedules fo be followed | 112(a) of Chg. | 5 Primary and 4 Secondary trains in coaching depots Manual and | maintained To maintain coaching stock in good | Correction slip § for condition, the following maintenance | coaching schedules are prescribed to be carried out | maintenance manual in carriage depots on divisions where rake | issued in 2008 has been based for primary maintenance, 3. [Schedule A Monthly (1 month + 3| RB letter no. 2007™M [No coach Is run overdue schedule. days) in rake {_ cytait dtd | Records of around 20 coaches 28.08.08 checked. The MIS records are not updated for March, Details in coach register are in conformance | Schedule B -Quartery @ month & 7 days) No coach is run overdue schedule, in rake Records of around 20 coaches checked. The MIS records are not updated for March. Details in coach register are in conformance, 5. | ToH attention - detach coaches ‘One coach no.96265 was found where Pariodicity of 1OH attention: Coach Cetonory Periodicity atintarval oF 72 New coach months in Depot Rajdhant at interval of S| ‘Satabdi (Conv) |_months in workshop ‘at interval of Mail! Express | months in depot at interval of 9 Passenger months in depot at interval of 12 Otrer CVs | 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 IOH was done 10 days prior to becoming due as against tolerance of +30/-0 days. Staff counselled. More checks did not reveal any other instances. Appendix F followed for A and B schedules, IOH is done with unit exchange bogies from workshop, Air brake items like PEASD and DV are tested. Amenity provided where missing. Intensive cleaning and single car testing carried out as per Appendix G. Page 3 of 27 Coaching depot - Wadibunder, C.Rly. April 2012© | Primary maintenance schedules are) 112(5) of] Records checked. The coaches marked Foquired to be carried out by the base | Chg Manual sick at the other end are getting returned depots to which coaches are alloted. In to base depots by WB in the subsequent emergency, when due to any reason inp. coaches cannot reach their base depots and primary maintenance schedules become due, A & B schedules should be Undertaken by the carriage depois where the coaches are available, ‘C’ schedule should be done at base depot 7__| Examination of originating trains 107 _a of cha Manual T1_[Al tains must be examined by the | 107 a () of Chg. | Done mechanical train examining staff before | Manval despatch to ensure all coaches are in fit Condition without rejectable defects, 8. | Terminating Examination of Passenger | 107 _b of Chg, | Carried out at CSTM station, Rolling in Trains - Rolling in examination Manual lights are provided. 8.1_| Site shall provide unobstructed view of | 107 —(o\@) _ of | The site provides unobstructed view of Under gear from both sides. (Chg Manual under gear. ‘B2_| Should have adequate space for ing the | 107 _(NN@) of | Lights are avallable. Adequate space lighting arrangement and for staf Chg Manual exists. Ba_| As the Wain passes the nominated pat, | 107)" ‘of | Checked for CSTM. During rolling in of C&W staff should watch out vigilantly for | Chg. Manual Pushpak Exp. On 03.04.2012. Control loose/hanging/broken under gear parts of messagel Phone message from PIF are the coaches, any unusual sound coming recorded in the log book. Last message from the coaches or any other abnormality from PIF on 31/3/2012 for wheel skidded in the coaches, in an ACCN coach BA_| Temperature of the axle boxes should be | TO7(B)) of] Electronic temperature sensors _are measured preferably with the help of the | Chg.Manual available al CSTM platform. Batteries electronic temperature measuring device. replenished through imprest. 3. [Revised maintenance pattern for | Railway Boards | No JPC is available coaching trains circulated vide Railway | letter Board's letter No.95/M(C)/141/1 | No.95/M(C)/144/1 31.01.07 t.31.01.07 ‘BA While permiting introduction of round trp | Railway Boards | CR Headquarter letter citing Northem Primary pattem of maintenance on | eter Railway reference available in the depot. Coaching trains, approved mandatory | No.9S/M(C)'144/1 Condition at primary end and other end as | dt.31.01.07 detailed in Railway Board's letter No. 95/N(C)/141/1 dt:31,04 07 is followed. it Primary End ‘Check record and also check rake and write observation | The brake gearing should be properly | -do- Brake gearing checked by a gang of four adjusted including the slack adjuster ‘A’ artisans. A dimension of BMBC coaches dimension & the brake cylinder stroke to checked and recorded. Checked rake of ensure 100% brake power 12137 (Punjab Mail) with Sr. DME/C CSTM alongwith the depot incharge Sh. Nagpurker and gang on 03.04.2012 T)__ | Brake blocks should be changed in bogie | -do- Not being done. They are being changed sets only a a set for brake beams. ii) [All missing passenger amenity fittings | -do- Based on availabilty as per depot must be replaced and the rake must be incharge. Sufficient quantity of bottle turned out as ‘Zero-Missing-Fiting’ rake, holders is not available. However in the rake checked, deficiency was not seen W) [Intensive clearing of coach Tollts and | -do- Done during maintenance, The availabiliy lavatory, and use of chemicals, Nylon brushes and ‘Scrubber machine was checked on the Page 4 of 27 Coaching depot - Wadibunder, C.Rly. April 2012‘spot for availability and practice, VW | Gear maintenance tme of 6 hours on the | -do- ‘ceassionally not available for train pit as per train schedule no,12141 (CSTM-Rajendra Nagar) due to deployment of lie over rake elsewhere (12141). Not available for 1093 (Mananagri express) for primary maintenance due to delayed arrival wi) | Provision of proper washing cum | ~do- Yes. Available maintenance pit ine facity with adequate testing equipment and high pressure jet cleaning plant at primary end vil) | Adequate gang strength with proper | -do- ‘Yes. Available. supervision Bz | The Other End ‘Check record and also check rake and write observation | Whenever the Tie-over & more than 2 | dom ‘Only one train Pushpak (2533734) has Tre hours atthe platform or the rake is stabled over of more than 2 hours and it is in the yard the rake should be locked and brought in the pitine. 16 RBPC trains are postive security should be provided received at VT out of which other end attention is provided to 12 trains in nominated stabling lines at the station itself 4 trains are platform returned. | The minimum infasiructure to be provided | -do- High pressure pipe line and Apron not at the platforms. from where tains are available al stabling lines at VT. returned without secondary mainlenance shouldbe is available Ti) A joint safely cerificate covering each | -do- Maintenance pattem of tains has not clause of mandatory conditions wil be been changed in the last three years, issued by mechanical and operating Joint Safety certificate not available in branches at’ divisional level prior to depot changing over any train to revised coaching maintenance patter, T0.] Rake mantonance link has provision of | 108 of Chg. Manual | Rake link and occupation chant checked. maintenance time (pitatention) of 6 hrs at | and Policy circular | Adequate time is nol available for 12141 primary end to enable intensive attention, | no, 4 wherever lia over rake is not available. In case of delayed arrival of 11093 also, the time available on pit is close to 5'/, hours only. Similarly 2859 ( Secondary) gets only 5 hours on pit as per occupation chart T1-| Tntemal dearing, Passenger ameniy | 108 of Chg Manual | Adequate depot infrastructure is avalable attention and watering is done at platform |Table 1.8 Nominated line available at CSTM station line or nominated stabling line provided but washable apron and high pressure stipulated faces are avaiable at such pipe Ine for cleaning is notawvalable in line is fllowed Fipe line for leg 72] Washing and cleaning of coaches 70a of Chg Manual 721 | Use recommended soliions for leaning | 109 of Chg Manual | Approved cleaning compounds are being as per RDSO specification No. used. Taski Rand R3 available in the MECIPCN/101/2001 or use cleaning depot. agents approved by CME ofthe Railway 722] W shoukd be ensured that the rakelcoach | 109 (bya) of | Yes. Men at work board is available and is protected with proper board/signal for safely of the staff working on washingicleaning job to prevent movementidisturbance in the activity Scotch blocks with locking arrangement should protect fines and keys should be kept with Engineer (C&W) til the time rake (Chg. Manual in use. Page 5 of 27 Coaching depot - Wadibunder, C.Rly. April 2012Tg under maintenance: 12.3 | External cleaning washing: 109) (b) of | Checked in the rake of 12137 and 12141 Check that guidelines as detailed in | Chg.Manual Being followed, CANTECH manual are being followed 724] Cleaning of Tie: TOS _—{e)__ of] Checked in the rake of 12137 and 12147 Check that guidelines as detaled in | ChgManual Being followed CAMTECH manual are being followed. TZB_| Iniemal deaning of upper class AC and | 109___{@) of | Checked the rake of 12137 and 12147 sleeper coaches: Chg. Manuel Being followed. Check that guidelines as detailed in CANTECH manual are being followed 725 inlemal deaning of GS, SLR To3r) OF | Checked in the rake of 12137 and 12147 Check that guidelines as detlled in Chg Manual Being followed. CAMTECH manual are being followed 72.7 | Cleaning of buffers and screw couplings 1050) oF | With wire brush Chg.Manual T)__| Bulfer plungers should be scrubbed with a | 109(f)) ‘of | Cleaned with wire brush and oil applied. seraper to remove dit and muck Chg Manual Thereafter, they should be wiped clean with cleaning oll and rubbed with coir rope T_| Screw coupling threads should be cleaned | TOSI) oT | Only spare screw coupling Is cleaned. with wire brush to remove all dit and dust. | Chg.Manual Thereafter, it should be cleaned and given a light coat of oil. Oiling should be done an Slack adjuster also 73] Conditions required for maintenance of | 170 of Cha Manaal 24 coach trains (Railway Board's letter Nosem(cyi37/19. Pt dt287.99 & 55.2000, 75.1] Infrastructural requirements Toa) of Chg Manual | 2 coach engin uly equipped pit tine. | 170¢ayi) oT | 26 Coach length Pit ines avaliable Chg Manual TH _| High pressure jet cleaning pipeline with | T70(ay) oF | High pressure jet cleaning pipeline are plant for cleaning at primary pit line. | Chg.Manual available in the maintenance line and are. Mecanizes extemal deaning 8 extensively being used preferable i_| Water hydrants for 24 coach fengih at en 170(ayti) oT As told by the depot, he watering station route watering stations with 20 minutes | Chg Manual ‘at BSL has the necessary facility, Could stoppage at nominated stations not be verified Hy _| Availablity of the prescribed airbraxe 1 70(ayiwy 2F | Available, With calibration periodicity of 6 maintenance and testing equipment Chg Manual months separately forall the four examination lines. 732 | Coach Design related requirements 170) cy Chg Manual TW _| Airbrake with win pipe graduated release | 170(0)() | Yes system Chg Manual Ty _| Oniy enhanced capacty draw gear and | TIO) oT Yes screw coupling to RDSO. sketch No, | Chg Manual 72081 and 79067 are to be provided on the rake 733] Maintenance practices and system | 170) oF Quantum of regularly to be indicated related requirements Chg Manual The integnty of the rakes to be 170(e\) oT | Cannibalization of rakes isnot prevalent maintained Chg Manual However spare stock is used between depots of DDR, MZN, LTT, and VT in the Mumbai area. iy | Primary maintenance of the rake should ] T70(e) oF No spliting is done. be done inane hook without spiting | Chg Manual Page 6 of 27 Coaching depot - Wadibunder, C.Rly. April 2012ii) _] Minimum maintenance tne of 6 hours on | 1TO(@\i) of] Available, Exceplions as reported 9.1.1) the pit during primary maintenance Chg Manual WI is mandatory to provide secondary | T10(e)(v) oF | Being followed. 12859 gets only 5 hours maintenance to all rains augmented to 24 | Chg. Manual on the pit due to delayed placement on coaches (RPC 4 revised and. permit ‘ccount of path from VT. Roun trip. attention with approval of ME) VW _| Trains Teakage rate to be _maintaned | TO(eV) oF | Being checked, Well within Ink within preserved limits by using rake test | Chg Manual rig W) | Provision of proporionate brake system | T1OTe)(™) TNA on the locometve in good working order Chg Manual Wi) | Provision of audio visual alarm system on | 170(e\(vi) oT NA the locomotive Chg Manual 7a] Fire_ extinguishers should be checked T7170) oF | Being done. The new and released every three months and completely efled | Chg Manual extinguishers are properly segregated ‘after one year. Issue is from centralised stock at VT. Depot was advised to use up the extinguishers retumed on expiry for fire safety drils to train staff and prevent round tripping Ta] Provision of DCP ype fre exingusher in| RBS —Teler no, | Being followed a rake should be in accordance with | 95iSec (spIN76)1 dtd Guidelines circulated vide leter no. 95(Sec | 30.05.97 (SplV75/t dtd 30.05.97 [Coach ype ——[ Nos of E'S] Each Break Van 12 nos Each AC coach | 2 nos Each Panity car — nos Each Generator | 2 nos 75] Similarly, other brake van equipment, | 11 Tle) of | Checked SLR of 12137 Punjab Mail by ‘which Mechanical Train Examining staft is | Chg Manual breaking the one time lock. Portable Train responsible to supply, should be provided Lighting equipment was rt available in according to the. instructions of each to Guard Vane The joint Inventory memo Raihiny” Ferable, contol telephones, is not boing signed by al the departments Portable fre’ extinguisher," wooden except Mechanical. Sr, DME was advise Wedgesiskids and stretcher are to. be to ensure and advise Sr. DSO about this. provided, 76-| Watering and cleaning of rakes Tiny oT | The depot does nat have information in Mechanical department of each railway | Chg Manual this regard beyond CR territory will nominate the watering andthe cleaning stations onthe railway V7] Deficiency Rolling Stock (ORS) for Ti) (or Coaching Stock T_[ Railway should devise system for | Chg Manual Printed proforma of DRS cards avaiable. detecting — deficiencies, Reports of But it is not being signed by RPF and (one) pert defects in ons Stock Guard. Checked for 12137 Punjab mail of reports in the proforma given ni ‘ Annexure 1.2, should be prepared for 2104/2012, each mallexpressipassenger org nating train. in duplicate by te Engineer (C&W)Electrical (TL) and should be signed joint withthe RPF representaives, TH] On arrival of the Wain at the destination | T7TS)O) oF | Not being done as the rakes immediately station, the Engineer (C&W) staff-and | Chg. Manual locked and moved out of CSTM electrical staff shall check the rakes jointly with a representative of RPF and comparison may be made with orginal report Individual theft reports are being sent from rake maintenance as and when required. Page 7 of 27 Coaching depot - Wadibunder, C.Rly. April 2012Coach Maintenance History Gard TH oF Every coaching depot shall_have computers for maintaining the coach maintenance history in a software programme which should be compatible with the programme of the coaching workshop, ‘Chg Manual Local ORACLE based MIS not compatible with MTN shop. @ The complete history book of each coach, Consisting of maintenance history cards, date card, rial card, etc. will, however, be maintained by the base workshops Tou (Chg Manual of ‘Could not be verified in the depot 7, Primary/Secondary maintenance 194 The rakes! coaches of all rains should be given a Primary/Secondary Maintenance examination as prescribed by the Chief Mechanical Engineer of the Railway and as per Appendix F of Cha Manual T731a) (Chg. Manual of Being done in accordance with Coaching Maintenance manual and RPC IV 792 Coaches shall be washed and cleaned thoroughly from outside and inside as prescribed in clause 109. T1315) (Chg Manual of Being done. Page 8 of 27 Coaching depot - Wadibunder, C.Rly. April 2012753] Brake system maintenance TSE) oF] Being. done The depot does not have Air brake system (Bogie mounted and | Chg.Manual underframe mounted coaches in_ its underframe mounted): holding. For coaches in the secondary Attention as detailed in para 113 ( ¢) is maintenance rakes, the staff is boing given cre primary eeconiery conversant with the underframe mounted system also. TS _| Tr addon t above the folowing fame of | T1718) ot | Boing done. Crilical areas of bogie frame Work. should be attended during” the | Chg Manual are wiped for closer inspections. In the mmaitenance schedule examination rake of 12137 following were being Undarames checked * bogie frames Underframe: Trough floor, turn under Sole 1 pl bores bar and headstock 8 Bogies: Last coil of springs, Spring Plank, These items should be wiped with wet Hangers ,Brake beam and Axle box wings waste weaves or cation. waste as were seen being checked after wiping out necessary so as to facliate examination the muck Bilunder gear components should then be ‘Axle box: Bolts, oozing of grease from examined and repaired as necessary to rear cover, and wings were being wiped ensure. that there is no 'S) marked before Inepection Tejectable defect as mentoned in Chapler Ivo IRCA Conference Rules. TSS] the folowing toms of undergear | T13__(@) af components should, however, be specially | Chg Manual examined and attended to i) Oil in hydraulic dash pots of Rajdhani and | 173° (e) (i) of | No Rajdhani Shatabdi coach is available Shatabél coaches should be checked | Chg Manval inthe holding of the depot once in 18 days to detect al leakage from trom "ough defective seals or hough the vent screw. Add! replenish wih speciied grade of ol if te ol level is Below 40 mm in the tare. conaton for ensuring beter ring cmon W[Wheet »proties should be —_wsualy | Tay) GF | Being done. Gauges avalable and sick examined and gauged in case they | Chg.Manual marking details indicate that coaches are appear tobe near condemning limits. indeed being examined Ti)__| The brake gear shouldbe checked and so | T7@(eV)___of | Being checked and piston stoke © adjusted thatthe piston stoke 's win | Chg Manval recorded in the proforma available the limits speciied for diferent types of coaches. (See table 1.10). A and e dimensions for slack adjuster should be 8 per ‘able 1.11 (as applicable for under Frame mounted brake system) TBS_| The following coach body components | 11S (of and fitngs should be specialy checked | Chg Manual and atended to Doors shouldbe propery secured with he | TINT OF | Checked in the rake of 12137 and 12147 hinges/pvots and should not be grazing | Chg Manual Being followed with floor or door sl plates I] Boor itches and safety caiches TaN oF| Checked in the rake of 12137 and 12141 Chg. Manual Being followed. ii) | Door lock handles 11 3(f(ii) of | Checked in the rake of 12137 and 12141 hg Manual Being followed. ia) Tower bls Tra) oF| Checked in the rake of 12137 and 12141 (Chg.Manual Being followed. W_| Window shuts shoud reiter be Tare Tam) GF] Checked in the rake of 12137 and 12147 nor loose (Chg. Manual Being followed. ‘a _| Window shut satay catches Trai GF] Checked in the rake of 12137 and 12147 (Cha Manual Being followed. wa_[ Window Fame T13iH(vi)_ oF | Checked inthe rake of 12137 and 12141 Chg. Manual Being followed. Page 9 of 27 Coaching depot - Wadibunder, C.Rly. April 2012Wil) ] Vestibule assemblies of all vestibule | 113(0(vi) of] Checked in the rake of 12137 and 12141 coaches should be checked and repaired | Chg Manual Boing followed. as necessary. im) _| Water pipe connections, flushing valves, | 113100) of | Checked in the rake of 12137 and 12141 cocks and shower hoses should not be | Chg Manual Being followed. leaking or choked %) [Drain gills and drain holes ih the | Tao ‘of | Checked in the rake of 12137 and 12141 bathroom floors and wash basin | Chg Manual No choking seen, drainpipes should be cleaned and opened where found choked 3H) [Any other deficiency as per Annexure 12 | TT3(No) oF should be made good. (Chg Manual xi) [A proper record should be Kept by | T13(h) of | No DDR is being maintained. Records of Engineer (C&W) at washing/pit lines of | Chg Manual ‘Schedules are however kept coach-wise schedules carried out by them, in diaries. The records in the MIS were especially of items required to be mot updated for March't2 attended at specific periodicity Record to be maintained in standard DOR (Damage deficiency register) 20:| Schedule ‘A’ Examination 114 of Che Manual | Schedule A's requiredto be gven every | 114 ___(@)___of | Periodicity is adhered to. It was month + 3 days at the nominated primary | Chg Manual suggested that the depot followed the maintenance depot within the normal Maintenance manual format, primary maintenance time on a ‘washingipit line in a rake. i. | Brake system maintenance THA) of | Being followed. Changes in format Air brake system (bogie mounted) (Chg Manual suggested. AA schedule maintenance as per alr brake chapter |The speciied tems of work should be | T1410) of | Being followed attended during Schedule ‘A’ examination, | Chg Manual i.e, monthly examination: 2_| Schedule" Examination 115 of Che Manual i, _ | Schedule Bis required to be given every | 115(@) of | Being followed three months + 7 days at the nominated | Chg Manual primary maintenance depot within the normal time allowed for primary maintenance on a washing line in rake, T._[ The specified items of work should be | 115(5) of Being followed attended Ti, | Brake system maintenance Chg Manual Being followed, Recorded in maintenance Ar brake system (Bogie mounted) diary with signature. () Same as ‘A’ schedule wv. _| Other assembly maintenance Besides brake system other items should | 115(by() of be attended as given below. (Chg Manual ‘@_| Alltems of Schedule Ts of | Followed (Chg. Manual B.__ | Painting of lavatories from inside. Tv) of | Lavatory floor skirting is painted. Pipes (Chg Manual and panels painted as per requirement. | Tharough inspection and repars of brake | T75(6)(0) ‘of | Done. gear components Chg Manual @_| Thorough checking of tough floor, tum | TSI) of | Done. unders, et, from underneath’ for | Chg Manual Page 10 of 27 Coaching depot ~ Wadibunder, C.Rly. April 2012& | Touching up of painted portion, Waded or | TTSIb)Qa) a] Done, soiled (Chg Manual 72, TOW attention Tie of Cha. Manval and Corecton slip 5 for coaching maintenance manual issued in 2008 2a] Periodicity of OH atention: Ti7()_ of Chg. | Followed. Remarks same as lem 5 Coach Manual above Categor Periodicity and correction slip § atienalet72—] for coaching New coach months in Depot _|| maintenance manual Rayan ‘atinterval ofS —]_ 'ssued in 2008 Satabdi (Conv) | months in workshop at interval of Mail / Express months in depot at interval of 9 Passenger months in depot atinterval of 12 Other OCVs months in depot ‘Tolerance Tor TOH may be Kept as 300-0 daye, Maintenance activites to be carried out during. schedules should be 93 per Append & 6. For 1OH attention of newly built coaches, guidelines 95 circulated vide R's letter fo. 2007IM{ C)'41/ ata 06.08.09 ZEZ| Coaches are requred'to be detached Fom 1771) oF | Being detached. 1OH cared out in the the rake and taken to the sick line or sent | Chg Manual IOH shed to shop for IOH attention ((C" schedule | and Correction sip 5 maintenance) for coaching maintenance manual issued In 2008 ZZ3_| Brake system ~C sched mainionance | 117ia\i) oF | Carried out (JOH) 28 per para 426 of ar broke | Chg Manual chapter Za] thoroughly dean Dit colecor erm Ti7(ajwy of | Being done kerosene or replace on contin basis. | Cha. Mandal 225] Other assemblies maintenance TaN) oF | Being done Allitems of Schedule "8" Chg Manual 225 | Thorough repairs of running gear Ti7(@ya) & | Being followed. All coaches are being including. running out of bogies wnere | Chg Manual given |OH considered necessary. All bogies which are working. on rake links earning more than 25 lakhs kms. per annum must however be runout” and thoroughly attended to.as laid down in clause 111¢ Linder “Intermediate Overhaul. Zar | Touching up damaged pant of coaches Ti7Tala a Touch up & being done and seen on on outside as well a inside hg Manual coaches. Depot has also started screen printing the seat no. on the side wall. Two coach doors were suggested for touch up painting in the rake of 12141, 2Z8_| Polishing ofthe polished surfaces TaN) NIA hg Manual 22a | Shock absorbers shoud be replaced and ] 117(a)() oF | Adequate spares are avaliable sent fo the base workshops for repairs, | Chg Manual testing and retum, For this purpose, adequate spares must be maintained in the depot Page 11 of 27 Coaching depot ~ Wadibunder, C.Rly. April 20122.10 Thorough cleaning and removal of dust rust, dit, ete,, accumulated at tho pillars through the turn under holes, with coir brush and compressed air. Tia) (Chg Manual Not being done. 2a Thorough examination and repare of Upholstery, cushions, curtains, etc Ti7awy (Chg Manual of Being done, DAZ Thorough checking and full repairs of all window shutters, safety catches, safely latches, staples and hasps.— of, compartment, lavatory, Tima (Chg. Manual of ‘On the two rakes checked on the spot. Windows were properly maintained including smooth running of window shutters, cleaning of glasses, balancing mechanism and working of safety catches and latches. BAS Thorough checking and repars of UIC vestibules, their rubber flanges metal frames, doors, fall plate, locking gear, etc. for ease of operation and safety. Ti7aNe (Chg.Manual of No repaired UIC vestibules were seen. Fall plates were sturdy and supports were firmly in place. Better cleaning of support bracket was advised. Ae Thorough checking and repairs of all cracks and wom out portions of flooring of the compartments. THT(ayo (Chg. Manual of Being done. AS 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, et. For facilitating inspection of ‘sole ‘bars even spaced elongated holes of (215x127 mm) ate already provided in the tum tunders, 7 @ (Chg. Manual of Rake TXR of 12137 Sh Sanjay Rankhabe and Sh. Ramesh Behra JE were ‘questioned and found to be aware, DAS ‘Special allention should be Taken or the following:- 1718) (Chg Manual of Pocket between sole bars and turn unders should be thoroughly cleaned through the inspection opening of the sole bars and inspected with the help of torch light or Inspection lamps. TIEN) (Chg.Manual of Cleaned and inspected with Torch lights, W. Drain foles provided in the ough 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 TI7(eyhi) (Chg Manual of Drain holes checked and were found clear Ty ‘A register should be maintained of the primary maintenance coaches on the subject. Record of Schedule A, 8 and 1OH attention are maintained in standard format and records are maintained. Tien (Chg. Manual of ‘Coach wise records of scheduled and out of course repairs are available. BAT For maintenance of coaches of RajdhaniT Shatabdi Express Rakes, the instructions given in ROSO Technical Pamphlet No, -7807 should be followed, io) (Chg. Manual of Not Applicable 2.18 The IOH of Rajdhani/Shatabal high speed coaches should be carried out in ‘workshops 1181) (Chg Manual of Not Applicable. es Linen management Complete adtviy of linen management including washing, storage, supply & Boards Tatler No.2009)M(C)/165/6 Not being done as linen distribution in ‘some of the trains has not been handed Page 12 of 27 Coaching depot ~ Wadibunder, C.Rly. April 2012Gstibuion of ten Kis ih Wains shall be | G17 12.2008. ‘over by Electrical dept. done by Mechanical (CBW) Dept as a single window agen Tl@y_[ Stock venficaion of Tinen should be | Soard’s Teller | Guarlerly slock verifealion is being done. cartied out on a quarterly basis No.20097M(C)/16516, TB) PAL least 5% of new linen should be | dlé.t.2010 Nat being done Tor new Linen: checked by SSE/Mechanical for (@) bundles being sealed and having batch nos., manufacturer's name, year of manufacture, quantity, size indicated {b) Linen terns having marking of month / year of manufacture, Railway, etc. {c) dimensional check, colour, fee! and workmanship, etc. [ey] Monthly report of nspecions Test checks ‘Quarterly checks of contractor’s premises of the linen washing contractor's are being carried out. premises by officers / supervisors, should be prepared and payment should be made afte recovery of all penalties / dues, T{@)__| Enough buffer stock of inen toast for 2 Buffer Stock: 61000 Pillow covers, 48000 3 days is available face towel, 114,000 bed sheets on date, Tle) Life ofinenis adhered to Life of linen is adhered to. Condemnation Bod sheets: 12 montis for khadi, 2. in March was as under: months for poly vastra 3914 bed shoots, 2040 Hand towels, Pillow covertiace towel : 9 months 5312 Pllow covers, Pillow : 24 months Blanket : 48 months TH] Commitee nominated by ORM Tor Ten No committee Is nominated condemnation on condition basis | Specified frequency of _washinglary Not being adhered to for blankets. Total cleaning of blankets and other linen items £8431 blankets. Washing: March 320 no. is adhered to February 523 no, Z51_| Passenger complaint on account of nen No feedback at Depot. The feedback is is analyeed and corrective & preventive with the VT depot forall the train linen, action is taken 252 |Feedback on nen quality 1s oblained Feedback is gen at VT by coach through coach attendant as per RB's attendants upon arrival guidelines Ba} Pest / Rodent Control 7] Comprehensive contract covering pest | Board's Teter | Contract starled in June 11 for 2 years rodent conivol in coaches and fodent | No2010(M)CI141/7 | and five depots. CSTM, MZN and DDR Control in pit ines / coaching depot yards awarded for 3 years under two packet system Voll at.21.12,2010 yards are covered. WB yard is not covered as it is extensively concretised ‘All reserved (both AC and Non-AG) covered under contract, unreserved coaches may also be covered as per requirement of Railways Unreserved GSCZ coaches are also covered. GS and SLR are not being given Pest/ Rodent Control treatment, Minimum frequency of pest control treatment is adhered to ‘AC coaches | Panty cars : Fortnightly, Reserved Non-AC coaches : Fortnightly in first 3. months, monthly thereafter, Unreserved Non-AG coaches : Bi-monthiy Maximum tolerance +7 days, on account of operational exigencies, disturbance of rake inks, ete ‘Adhered to. ‘Chemicals to be used (with brand names), concentration, dose specified Chemicals not specified and itis left to the contractor who is allowed to rotate various permitted chemicals for efficacy Vv] Minimum frequency of rodent control Yes. treatment is adhered to AC coaches | Pantry cars : during every Page 13 of 27 Coaching depot ~ Wadibunder, C.Rly. April 2012Primary maintenance, Reserved Non-AC coaches : Weokly Maximum Tolerance #7 days, on account of operational exigencies, disturbance of rake inks, ete Personnel trained by cerlifed training institutes deputed for pestrodent contro! Trained and cerlified supervisor _is available as laid down in the contract. Sh. Ajay Jagannath Shahane and Shaka \Venkatrao Bagade are trained by CFTRI Fumigationimist teatment carried out whenever coaches detached for IOHIPOH, Pestirodent control carried out before inducting the coach in service after, IOHIPOH Followed. Vil, [In ofder to prevent cross infestation, Not rigorously followed. 2-3 adjacent contractor may make effort to treat all AC coaches are being treated together and all Non-AC coaches of a particular depending upon requirement and rake together periodicity ‘Stickers indication date of past control and next due date provided in doorwayitolet ‘Stickers are not being pasted. The date is stencilled on the end panel outside the coach. Sr. DME confirmed that they shall switch to stickers within a fortnight, Railways shall_make effon to detach pantry cars from rakes once a month (within reasonable tolerance) to facilitate Complete vacation and intensive cleaning for thorough pest J rodent control treatment Being done through sick marking, Broad methodology for measuring the level of infestation of cockroaches and rodents and expected reduction over time is in place ‘As par board's guideline for scale of reduction over the period of contract. ro Yas: required unscheduled veaiments bre analysand corestve acon also carried out by the contractor isten i) Passenger amenlies ROVERS VaPOIN | Boas THUS Bag prOVIGES types of coaches as specified No.2006/M(C)/141/2 Seuzrsaso0e i) astrasre —Teclies ———Siandard | Appana Et | Standard pi no wih wide anobstracod imegeted modulor pt ine Fave uned | Coscnng anal” | catwalts sper CAMTECH design maintenance, CAMTECH nn However, the pit line rails are supported NeCAMTECHINIS! | yy contmuous was rater than pars ier 2 Examination and ropa padice in Para 1009 of Chg cammage maintenance depot for wea | manuel sete and roller bering 277] Whee snails Fara 108 a Ta] neat quant a jection adavon to observation Wheel profile should be checked with Tyre defect gauge to ensure the profile dimensions are within the permissible limits, 141 coaches marked sick on account of wheel W Limits for at tyres The limits for permissible maximum fat surfaces on tread for BG ICF coaches is 50 mm (reference Rly. Bas Letter no. 83/M (N)/960/1/Vol I dated 15/18.3.99) Boing followed, iW Guidelines for whee! inspection in open line depots (Ref RDSO CMIK003) In addition to normal checks exercised on Guidelines for wheel inspection CMI KOS are followed. Page 14 of 27 Coaching depot ~ Wadibunder, C.Rly. April 2012‘wheel condition during primarylsecondary 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 acton taken as indicated for each condition ‘a)_| Shattered Rim b)_| Spread Rim ©) _| Shelled Tread @)_| Thermal Cracks @)_ | Heat checks 1) __| The defective wheel should be sent The depot has a wheel lathe which is out {to workshop for repairs after entering of order on date. All the wheels are being inthe maintenance card details of the sent to shop for repairs, work order and date of dispatch to workshop. YW) _ | No repairs, except wheel profling of Followed, wheel sets is permitted to be done in the maintenance depot. 272_| Roller Bearing Axle Boxes Para 1009 b of Chg | Indicate quantum of rejection in addition ‘manual to observation ‘Kcoath should invariably be detached from service forthe following defects i) Hot axle box il) Damaged axle box ii) Damaged front or rear cover Iv) Seized roller bearing V) Coach involved in accident, derailment, fire, flood etc. Being done. The warm box Is checked on arrival at CSTM. Spot check carried out in the evening of 03.04.2012. Sh. Ishwar Bagde Gr. Fitter was available at P/F 17 for checking rolling in of 12133 Pushpak Exp. Axle box temperatures were being checked with non contact thermometer of which two were available and only one was calibrated Wy Care Should be Taken nat to Keap coach fitted with roller bearing stationary for a long time. Coaches grounded for long lime 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 li) The front and rear covers of the axle boxes are not damaged, cracked or loose ili) 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 possibilty of brake binding Followed. 2721 | Axle box is examined for grease oozing Being checked for grease oozing on the ut from rear cover and corrective action rear cover during maintenance. is taken. Concerned shop needs to be advised for necessary corrective and preventive action. 27.3 _| Axle box temperature measurement by | Carriage Dle/RDSO | Being done. letter no. MC [AB dtd 21.08.09 ‘non contact lype temperature measuring instrument during rolling in examination: Temperature to be checked at axle box top (crown) at front face of axle Followed. Please see 27 2() above. iy If temperature is found above 80°C, the Ts being done, For Primary trains coaches Page 15 of 27 Coaching depot ~ Wadibunder, C.Rly. April 2012affected coach will be detached with 70°C on arrival are also detached 274 | Minimum permissible wheel diameter | RB Tetler no. 921M In ICH design BG coaches. (©)N37I2 Vol V dtd 254.11 1) _| Shop issue size of wheel set should be Followed. The depot has not received 837 mm diameter less than 837mm in ex POH coaches. | Condemning diameter of the wheel in ‘Gauge available and staff is conversant. service, measured at a distance of 66.5 mmm from the outer face of the rim shall be 825 mm. 28 | Attention brake block hangers on ICF | Carlage DtelRDSO coaches ~ to avoid failures letter no. MC IICFIBID dtd 03.07.08 2B.1_| The new brake block should be procured The depot is obtaining Brake blocks from as per revised spec C ~ 9808 Rev 2 and MTN store depot. The detalis of dg no. SK - 93286 Alt § purchased description are not available in the depot. The description procured in IREPS is for C 9809 rev. 4 of May ‘09 or latest. C-9808 is used for Brake block hanger. 2B2_| Maintenance of brake gear rigging should Being done. be given as per guidelines circulated by EDICarriage IRDSO vide letter no. MC JIGFIBID dtd 03.07.09 2 _| Other items: 28.1_| Changing of air brake hose pipe: Carriage Die/RDSO | Could not be checked as depot does not Air brake hose pipe to be changed in | letter no. MC /APB | maintain records. The hose pipes are every alternate POH attention. dtd 19.02.09 changed in the workshop. A few hose pipes on spare coaches were checked which were not more than 3 years (2 POH cycles) old. There were however new pipes of May’07 make make available in the substore 292 | Fire retardant Tems are provided in| RDSO spec and | Rexene, Curfains Laminates PVC ele. are coaches as per RDSO specification STR centrally procured by COS office to RDSO's fire retardant specifications as per IREPS. 253 [FAC ameniies are provided as per Carpets are not being provided guidelines circulated vide DGiCarrgiRDSO's —etter_ «no MGIGBIACIBG dtd 28.04.10 284 [Additonal amenities / ‘aciliies in GSCN | RB Teller no. 20047 | Full complement of snack tables not type of coaches are provided as under: | M_(C)/165/16 td | provided. > Snack table in each bay. 29.03.05 > Mirrors in each bay > Magazine holders on partition wall > Bottle and tumbler holder 255 _| Maintenance of Duronto express? 7 Patiem of maintenance for Duronto Wain as being followed for Rajdhani trains with pit examination at both end should also be foliwed, RB latter no. 2008/M (oytati2 ‘td 25.08.09 W Rolling — in and roling- out examination may also be conducted for each of the Duronto tains at the respective operational halts and also at the terminals during the joumey. Such safety examinations of the Duronto trains may be RB letter no. 2000/M (cyrati2 dtd 25.08.09 NO DURONTO RAKES ARE BASED IN WB DEPOT Page 16 of 27 Coaching depot ~ Wadibunder, C.Rly. April 2012Periodically super checked at the level of officers. i ‘Short distance Duronto with only only ACT Non AC chair car may be permitted to run fon the extant patter 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 tenable thorough attention to cleanliness, hygiene and passenger amenities at other end, RB latter no. 2008/M (cytati2 td 26.07.11 ™ Cleaning of Vinyl wrapping on Duranto rake coaches Mild detergent should be used with normal Jot of water. High pressure water jet should not be directed towards Vinyl ‘wrapping, RFs letler no, MD 22.151 ata 09.02.10 BES Rteatoh Oa apg EDICaRGROSOT Lee feter a rooadar Tr alg in Da aTOT fetrampassesthemomnated pa, caw | MCICBMM cd Sat shod wat aut aglanty Tose /| 09092000, & hang! Gren under gear parte | Maerance manual coaches special atenion should be pad | ,, a", sping for to air springs in case of coaches provided | ™2niNe a Mio apg, a semaay Seren acy Slo tsa be enuured ae a |RODSCI209 springs are in inflated condition by noting | “0t» SeP' bra he leveling wave. lover eB horton postion. Incase oot tobi ot the a sings ot any parted caach tase shuld ted By er apg ian cock ed epee ot hn shoul bo reac 160 gh ot he coaul shuld be dace BET anaiyaisof sick marking and onvouls Sach detache 7] titer pinay coach-aataaimen © By Gna GecRInOR are ara Dnahoed ard toner revenive tcton ian. “Dele of pnary fetscamart for last" years Yo" be soloed i] wetter secondary deiachnent bang Briary coach detachments are analyaed analysed and corrective & preventive 51 cases of secondary coach detachment action taken. Detalls of secondary ‘of WB based trains have taken place in detachment for ast "3 Yous tobe of. based 9 este i Weta -onrous ach deterrent Wo eiroute coach detachment oT WE Inesieted tnd coecive 8 srovrive opal nthe lat toe years solar ‘akan Dota entute conch Setacumart flan 9 year lobo eaocd stthesigaon ep 255 Panes ar pins and Sa Wo CANTEGTT sention Namtenance Moral T [Facts avalale a6 por CAVTEGHT for Coasnes of pulldnes av doaled h amenae Tis | 27 00,2 Be observed ie sin. 1 conection lp Ganiteorvacoin e cares. oifo7 208) 30 Fansenger tata Oct OBHS & escorng oan Page 17 of 27 Coaching depot ~ Wadibunder, C.Rly. April 2012