STANDARDISATION OF
INFRASTRUCTURAL FACILITIES FOR
CC RAKE MAINTENANCE DEPOTS ON
IR DEPOTS
IRCAMTECH/M/GWL/2017/STD. CC Rake Depot/1.0
MAY-2017
MAHARAJPUR, GWALIOR—474020
(Govt. of India)
(Ministry of Railways)
i
FOREWORD
As per Task Force Committee’s recommendations issued in the month
of January-2017, it was proposed to develop standard infrastructural facilities
required for CC Rake maintenance Depots. For this purpose, audit of some CC
Rake depots was planned and a team of CAMTECH officials was assigned the
work for preparing report. On the basis of field realities, the team was
instructed to develop report on above required infrastructure.
It would also be worthwhile to mention here that for strengthening of
infrastructure for freight examination yard, CAMTECH had already prepared
reports in 2003 & 2008 analyzing factual requirements for freight stock
maintenance in open line. After detailed study by CAMTECH team, it is
revealed that infrastructural requirements assessed in previous reports and
recommendations given in the past are still considered to be useful for freight
examination yards.
Hence on the basis of past studies on the subject and audit conducted in
recent months, a report has been prepared by the CAMTECH not only with the
efforts of CAMTECH officials but also from no. of Railway officers and
supervisors from Zonal Railways. In this report steps have been suggested for
increase in population of CC Rakes and in improvement in quality of train
examination.
In this report, the infrastructure facilities considered essential are; Standard
length CC Rake examination lines with specified pathways (depending upon
no. of rakes examined), Concrete path way & cross pathways, welding
facilities and portable welding sets for MS & SS welding, adequate illumination
level, pallets for material storage/dispensing, Road between office/store &
examination yard, FOIS connectivity, Mobile/walkie-talkie sets, provision for
transportation of staff and material/equipments to examination points, PPEs
and rechargeable LED head lamps etc.
(A.R.Tupe)
Executive Director
CAMTECH, Gwalior
ii
PREFACE
Task Force Committee vide his Report No.Jan-2017 had instructed
CAMTECH to suggest the Standard Infrastructural Facilities required for CC
Rake Maintenance depots..
CAMTECH personnel visited Mughalsarai/Eastern Railway, New Katni &
STA CC rake depot/WCR and Khanalampur/NRLy, TKD/NRLy,
Shambhupura/WRLy and interacted closely with officers and supervisors. Data
was also received from GIM, NKJ & STA
We are sincerely thankful to all officers and supervisors who gave their
suggestions, especially Sr. DME/Mughalsarai and DME/NKJ, ADME/STA,
ADME/Khanalampur, ADME/TKD, ADME/COR for their valuable comments.
Emphasis in this report has been given to have maintenance with
mechanized material handling facilities.
(K.P.Yadav) Director (Mechanical)
CAMTECH, Gwalior
iii
CONTENTS
Description Page No
Foreword i
Preface ii
Contents iii
1.0 Terms of reference 1
2.0 Objective 1
3.0 Methodology adopted 1
4.0 Observations 2
5.0 Recommendations 5
6.0 Basis for Major recommendations 9
7.0 Cost benefit analysis 11
Annexures
Annexure I: Proposed Lay out under covered shed 12
Annexure II: Wagon defect attention 14
Annexure III: Infrastructural facilities including M&P for CC Rake examination
in Yard
19
Annexure III-A: Hydraulic CBC Lifting crane 23
Annexure III-B: Specifications for 2 T capacity hydraulic CBC lifting crane 24
Annexure III-C: Specifications for Hand Operated hydraulic unit for removal of
CC pad & EC pad
25
Annexure III-D: Specifications of Hand Operated hydraulic unit for removal of
Springs
26
Annexure IV: Diagnostic System of TKD container Yard 27
Annexure V-A: Trial conducted at NKJ Yard 29
Annexure V-B: Trial conducted at PP Yard Bhilai 30
Annexure V-C: Flow Chart indicating sequence of activities 31
Annexure VI-A: Approx Cost break up for proposed facilities 32
Annexure VI-B: Savings and advantages of proposed facilities 35
Annexure VII: Specifications of abrasion resistance granolithic concrete
flooring
37
Annexure VIII: Overhead lighting fittings 40
Annexure VIII-A: Lightning arrangement for CC Rake examination Yard 41
Annexure VIII-B: Electrical Junction Box arrangement 44
Annexure VIII-C: Electrical Panel and Junction Box 45
Annexure VIII-D: Proposed Welding Transformers 46
Annexure IX: Photograph of Multi-utility Vehicles 48
Annexure X: Check List for CC Examination Point and Sick Line 49
Annexure XI: Recommended Illumination Level as per IS: 3646 (Part-I)-1992 53
Suggestions received during Seminar at CAMTECH on 28.04.2017 54
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STANDARDISATION OF INFRASTRUCTURAL FACILITIES FOR CC
RAKE MAINTENANCE DEPOTS
1.0 TERMS OF REFERENCE
Task force committee vide report No. Jan-2017 directed CAMTECH to
standardize infrastructural facilities for CC rake examination maintenance
depots..
2.0 OBJECTIVE
To lay down the requirement of facilities in CC rake maintenance depots
examining CC rakes of BOX-N, BCN, BCNHL, BTPN & BLC so as to:-
Increase the availability of rakes by reduction in total detention of
rake from placement to removal including examination and
detachment of sick wagons.
Improve in-service reliability of CC rakes
3.0 METHODOLOGY ADOPTED
3.1 The following reports/proposals have been taken into consideration:
The CAMTECH’s earlier report no. CAMTECH/2003/M/INF-
STD/1.0 of August 2003 for Standardization of Infrastructural
facilities for Freight Stock maintenance has been referred.
The report of committee of CRSE WR and CRSE WCR no.
2003/M(N)951/22 dt.21-08-06 for tank wagons and covered stock.
The Report on World class facilities required in Freight depots-Jan-
2008.
3.2 TKD yard was jointly visited with SSE/Incharge to study the
maintenance philosophy and the maintenance infrastructure for CC
rakes of container flat wagons.
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3.3 Khan Alampura yard was jointly visited with SSE/Incharge to study
the maintenance practices and the maintenance infrastructure for
BCNHL CC rakes.
3.4 Shamboopura yard/WRly was also jointly visited with SSE/incharge to
study maintenance practices and maintenance infrastructure for BCNHL
CC rakes.
3.5 Satna Yard/WCRly was also visited with SSE/incharge and audit
conducted for availability of infrastructure and maintenance practices.
3.6 Consultations have been held with officers and supervisors during
seminar at CAMTECH on 28.04.2017 before framing the
recommendations.
3.7 The facilities have been worked out for yards handling minimum 5 CC
rakes per day.
4.0 OBSERVATIONS : It was observed during audit of above CC rake maintenance
depots that the facilities presently available in most of the depots are not as per
norms in respect of the following -
a. Concrete Pathways : Most of yards are not having standard concrete
pathway between the nominated lines for CC rake maintenance. Material has
to be transported with listers or hand trolleys etc and portable welding sets
are also required to be moved for CC rake. Difficulties are being faced for
such movements. Minimum 2.0 meter wide pathway is essential for easy
movement of material and staff.
b. Distance between two examination lines: The recommended distance
between two examination lines in yard is 5.26 meter. But, in case of CC
examination lines, extra space is required for construction of pathways for
movement of listers, hand trolleys etc. Considering above factors, a clear
distance of 7.5 meter (centre to centre) between tracks has been proposed.
Extra space shall be required due to obstruction of OHE masts, lighting
poles etc.
c. Pit line : It is observed that pit line is not generally available in yard sick
lines. The pit line is required for brake gear repairs. In case of tank wagons,
pit line is essential to carry out valve repairs and other related fittings.
d. Road connectivity: - During audit it was also revealed, that many depots are
not well connected to the roads and cross pathways. Paved road connecting
examination yards and yard sickliness to municipal road is essential for
transportation of material & staff.
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e. Welding facilities :- Welding work is required to be done at CC rake
examination yard to avoid sick marking. It is therefore necessary that
welding line underground/ above grounded should be available with terminal
boxes on the entire length on alternative line at an interval of 20 meters.
f. Lighting arrangement :- The illumination level is generally poor in the
yards. CC rake examination yards must be provided adequate lighting
arrangements. Lighting requirement for working of staff are more than those
for general working. The recommended illumination is given in the
annexure-XI.
g. Material Handling facilities:- The material handling facilities for CC rake
examination yards were namesake only in the form of hand trolleys, pickup
vans for bringing material from store. In the major depots, Road trucks
should also be available.
Observations during audit in CC Rake examination Yards
1. TKD/NRLy CC Rake maintenance Yard
a. At AGC end one rolling hut is provided for 04 lines fitted with solar light.
Rolling in examination lighting arrangement should be provided for each
entry point.
b. 02 Staff should be deputed for rolling in examination on either side.
c. The condition of pathways should be good for easy movement.
d. Cross pathways are also required for transportation of material.
e. Sufficient tower lighting should be provided in the yard for general
illumination.
f. Tool kit should be available in tool bag for each fitter.
2. Khanalampura/NRLy CC Rake maintenance Yard
a. MB end rolling in examination lighting arrangement should be provided.
b. General illumination in yard is not available. Sufficient tower lighting
should be provided.
c. Precast paver blocks should be provided between pathway and rail line for
easy placement of hydraulic jacks.
d. No lighting pole provided for pathways to facilitate examination staff. This
arrangement is required.
e. Hinge type doors are being replaced with sliding type doors in yard for
BCNHL wagons.
f. Retrofitment is going on for repairing of doors in Yard.
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3. Shambhupura/WRLy CC Rake maintenance Yard
a. LED light is considerad to be useful for under gear examination.
b. BCNHL/BOXNHL wagons are getting damaged during loading and
unloading in sidings.
c. Body work (patch work & welding work on wagons should be added
in work distribution given at table 3.4 of chapter 3 of wagon
maintenance manual.
d. Running of CC Rakes on invalid BPC to be strictly restricted.
4. Satna/WCRLy CC Rake maintenance Yard
a. Cross pathway to be constructed in yard for movement of vehicles
b. Separate lines to be nominated for CC rake examination.
c. Platform with cat walk for maintenance and closing of BCNHL wagon
doors should be provided.
d. Separate sick line to be provided to attend sick wagons.
e. Covered Rolling in /Rolling out huts with lighting facility for staff to
may be provided .
f. Running of CC Rakes on invalid BPC to be strictly restricted.
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5. RECOMMENDATIONS:
For major CC rake examination yards dealing predominantly with
BOXN/BCN/BCNHL,BTPN & BLC wagons, the facilities would be as under:-
5.1 The Schematic Layout of the Proposed CC rake maintenance yard shall be as
per Annexure-I (A ) and I (B). The yards handling upto 10 rakes per day
shall have two Examination Lines of 750 meter each, one line for keeping sick
wagons and one line for keeping fit wagons released from Sickline. The mega
yards dealing with more than 10 rakes shall require doubling of these facilities
i.e. 4 examination lines and 2 lines for sick wagon and 2 lines for fit wagons.
5.2. Sick wagons and wagons due for ROH/POH shall be accumulated on the sick
yard line and thereafter pushed to sickline whenever the times permits.
5.3 The Fit line shall be used to keep wagons released from the sickline for
recouping the shortfall on account of the sick wagons detached from the rake.
The fit wagons shall be attached in one formation at the head of the rake with
the help of shunting unit.
5.4 Each Examination line shall be of 750 Mtr. each to facilitate creation of gaps
and the centre distance between the Examination, Sick and Fit line shall be 7.5
Mtr. to ensure free movement of material handling equipments and minor
attention. All tracks as far as possible should be in a straight line for a distance
of 720 m minimum.
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5.5 For the provision of Goliath Cranes, there should be no OHE wiring over the
Examination lines/Sick Yard line/Fit Wagon Line which shall be dealt with the
EOT Crane. Top wiring at both the ends of the train examination line can,
however, be provided for dropping the rake and for waiting for crew/loco after
release.
5.6 (a) A dedicated diesel shunting engine shall be used for placement of rakes in
examination lines if the rake is received with electric locomotive.
(b) A rail cum road shunting vehicle with capacity to haul 30 empty wagons shall
be used for creating gaps between wagons requiring detachment on account of
POH/ROH/Major repairs. The vehicle shall also be provided with compressor
and rake test rig for air brake testing of formations.
5.7 For yards handling upto 10 rakes per day, 7 EOT cranes of 30 tonnes lifting
capacity, 30 mtrs. span and 720 mtrs. travelling shall be provided. Each wagon
shall be lifted with the help of EOT Cranes by using specially designed slings
for lifting from Axle Box. The mega yards examining more than 10 rakes per
day shall have 14 EOT cranes.
5.8 At present there is no experience with Railways for handling
BOXN/BCN/BTPN & BLC wagons with Goliath cranes. As such the Goliath
crane can be provided in one yard for trials in terms of effectiveness and
maintainability.
Spare lines
Examination Line Sick yard Line Granolithic
Concrete Flooring
Examination Line
F it wagon Line
Line no. 1 Line 2
Line no. 3
Line no. 4
COVERED SHED WITH EOT CRANE
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5.9 Major sickline with all Infrastructural facilities would remain attached and
adjacent to freight examination yard.
5.10 The requirement of M&P is given in Annexure-III. In order to expedite
repairs In-Situ, adequate number of material handling vehicles and multi-utility
vehicles shall be provided.
5.10.1 For material handling, four wheeler pickup vans like TATA ACE can
be provided.
5.10.2 These vehicles shall be retro-fitted with a small DG set cum Diesel
driven welding plant, Gas cutting equipments, portable jacks for
changing EM pads, spring changing equipment, portable compressor
and hand tools, etc. in addition to this, the van shall have adequate
spares tools and equipments tools and few frequently required
materials like pins, washer, nut bolts, key, etc. required during the
course of examination. Nominated staff attending to these defects shall
also move by this van. Two focus light will be mounted on either side
of the vehicle along with one high focus headlamp. These lights shall
be swiveling type. Picture of one such vehicle is enclosed as
Annexure-IX
5.10.3 Hand operated hydraulic unit with jacks of capacity 5 tons & 20 tons
may be mounted on these vehicles for removal of C.C. pad, E.C. Pad
and springs. The sketch and specification of hydraulic CBC lifting
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crane and hand operated hydraulic unit for removal of C.C.pad, E.C
pad and spring is enclosed as Annexure-III-A to D
5.11 The complete area of the examination yard shall be provided with abrasion
resistance granolithic concrete flooring and ballast free embedded track to ease
movement of vehicles and material handling equipments. The specification of
Abrasion Resistance Granolithic Concrete flooring is enclosed as Annexure-
VII.
5.12 Illumination: The illumination around yard should be provided by high
intensity tower lights. The specification of light fittings and lighting
arrangement over shed area is enclosed as Annexure-VIII-A
5.13 In between sick yard line and examination line, electrical panel with junction
box at a distance of 30 meter shall be provided as shown in Annexure VIII-B.
Details of electrical panel and junction box are enclosed as Annexure VIII-C.
For welding portable welding sets shall be provided. The specification of
proposed welding transformers are enclosed as Annexure VIII-D & E.
5.14 Effective communication system preferably CUG mobile phones or walkie
talkie sets shall be provided across teams during the examination between
Supervisors, TXRs, drivers of EOT Cranes, drivers of multi utility vehicles and
shunting engine.
5.15 A system for position tracking of EOT cranes, multiutility vehicles and rail
road vehicle using active RF ID system to be provided for better monitoring
through yard office.
5.17 In order to reduce body repair in sickliness it is recommended that during
POH:
5.17.1 There should not be any partial and periphery repairs on the floor of
wagons during POH. The floor should be replaced by 100% new floor
so that it can last from POH to POH thereby reducing the load of patch
repair works in yard.
5.17.2 With the increase in average age of BOXN/BCN wagons, most of the
BP train pipe and branch pipe are getting perforated day by day. To
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reduce sick marking on this account, the replacement of 100% train
pipe should be a rejectable defect during alternate POH.
5.17.3 There are instructions for dropping of all CBC during POH which must
be ensured and no coupler/draft gear beyond condemning limit should
be allowed.
5.17.4 The damaged/corroded side stanchions should be changed completely
in workshops rather than patching.
5.17.5 The damages to the top coping between stanchion no – 3 & 4 is to the
extent of 28%. To reduce these damages, replacement of top coping
between stanchion no. -3 & 4 along with stanchion, door mediator and
doors should be in the form of a complete two pillar module.
5.18 The siding owners who are loading and unloading with the help of pay loaders
need to be disciplined as the boom of the pay loader and its tyres are hitting
the wagons. This can be replaced by, either conveyer loading system or hopper
system.
5.16 The sequence of activities as indicated in Annexure –V-C should be followed.
5.17 A comprehensive contract for day to day upkeep of the yard is recommended
for major and mega yards. This contract should cover items like scrap lifting
and bush cutting in the periphery of the yard.
5.18 A running contract for petty repairs pertaining to shed and floor of the yard
including civil and electrical engineering works is also recommended. This
contract shall be monitored by field officer of Mechanical Department.
5.19 A running contract for maintenance of all major M&P such as EOT cranes,
compressor, vehicles, welding sets, hydraulic jacks is also recommended.
6. BASIS FOR MAJOR RECOMMENDATIONS:
6.1 In the present system of working it is not possible to have a detachment
free train examination yards because of following reasons:-
6.1.1 Roughly 46 to 59% detachment of wagons are on account of
ROH/POH. At present most of the workshops are not turning out
wagons after POH in the form of complete rake. Moreover even if a
complete rake is turned out, the integrity of rake is difficult to
maintain as 4 to 5 wagons get detached for sick marking due to
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various reasons during each examination. Apart from this, rake
integrity is also disturbed because of replacement of embedded
empties even when the rake is not due for examination.
6.1.2 During examination of wagons, on an average 37 to 49 % of sick
detachments take place on account of body defects, particularly in
case of BOXN wagons. These defects require panel welding/floor
repair/patches on pillars/structure, which normally takes 2 to 6
hours on an average for rectification in sickline. Moreover, as per
present practice ‘petty repairs’ involving not more than 8 man
hours are carried out in Examination Yards. Instead of this practice
it is recommended that repairs which can be carried out in less than
10 minutes only should be attended to in-situ, rest of the wagons
should be detached. If we plan to rectify even major defects IN-
SITU complete rake will be unnecessarily detained.
6.2 As it is not possible to have detachment free train examination, these two
possible alternatives for replacement of sick/POH/ROH wagons are :-
(i) Carrying out shunting as per existing practice.
(ii) Lifting of complete sick/ROH/POH wagons with the help of
Goliath/EOT cranes
It has been found that maximum detention takes place on account of
shunting. Even if shunting neck is free, each detachment can take 30 to 45
minutes, whereas during the trials carried out at PP yard, Bhilai and NKJ
yard, it has been found that one wagon can be lifted and placed in another
line with the help of cranes in about 6 to 10 minutes. So in order to
achieve, the objective of reducing the total detention of rake to less than 6
hours, lifting of wagons is the most suitable alternative.
6.3 The two possible alternatives, for lifting of complete wagon and placing it
on a specially nominated sick yard line are:
(i) Covering the complete examination yard with the
covered shed and providing a number of EOT cranes.
(ii) Keeping the shed open and providing Goliath cranes.
Out of these two alternatives, Ist alternative also offers additional advantage of
improving the working conditions making it all weather examination depot with
better illumination. Moreover at present, Indian railway is not having any
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experience of handling BOXN/BCN wagons with Goliath cranes and the cost of
shed with EOT crane is comparable to that of Goliath cranes. (The cost of
providing covered shed over an area of 720 m x30 m i.e.21600 sqm is estimated to
be around 31.2 Crore Rupees and the cost of 7 EOT cranes is Rs.5 Crore, thus the
total cost is around Rs.36 Crore, whereas the cost of 3 Goliath cranes is Rs.27-30
Crore). So keeping in view the overall benefit, favoured Ist alternative of covering
the complete examination yard with the covered shed and providing a number of
EOT cranes.
7. COST BENEFIT ANALYSIS
Estimated cost of the recommended facilities for a major yard handling upto 10
rakes per day is 46.77 Crores as per details given in Annexure- VI-A. It has
been estimated as per details given in Annexure-VI-B that by providing these
facilities, 4.65 rakes would be additionally available for traffic use per day per
yard (handling 10 rakes per day) These 4.65 rakes can generate an additional
net annual revenue of Rs.74.63 Crores to the Railways.
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7.5 M
7.5 M
7.5 M
2.5 M
5 M
Exam. Line
Sick yard line
Exam. Line
Fit wagon
Line
Spare lines for
traffic and
Continuity and Safe
to run examination
with OHE
L-1
L-2
L-3
L-4
EOT cranes
Annexure - I
Proposed yard under covered shed
Annexure-I (A)
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Toil
et
Computer Room Room
JE/SE
Sta
irs
Sta
irs
Toil
et
RoomStaff
Admn.Room
RoomBattery
RoomStore and Tools
RoomSSE
OfficeSSE
RoomCompressor
Meeting Room
Heavy materialStock yardand scrap yard
Corridor
Motrable Road Motrable Road
Mu
nic
ipal
ap
pro
ach
- M
otr
able
Ro
ad
Heavy Stock yard
Fit wagon line
Examination Line
Examination Line
Sick wagon line
Spare line for traffic and continuity and safe to run examination with OHE
Garage Parking
Granolithic Concrete Floor
Granolithic Concrete Floor
Legends:
Location of sockets for welding connections etc. cable below
ground level
Tower light arrangement
Note:
All dimensions are in meters
Drg. not to scale
4 10 10 4 7 8 103 30
7
3
7
3
FloorFirst
FloorGround
Yard
Yard
Yard
LAYOUT FOR WORLD CLASS FREIGHT TRAIN EXAMINATION YARD
RoomDG set
Annexure -I (B)
Control
Yard
Room
Covered shed with EOT crane
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Annexure-II
Wagon defects attention in present scenario and with proposed facilities
Present Scenario With proposed facilities
Sl
No.
Defects Examinati
on line
Sick line Examinatio
n line
Sick
yard
line
Sick
line
A Wheel Defects
1 Deep Flange √ √
2 Hollow Tyre √ √
3 Skidded √ √
4 Sharp Flange √ √
5 Thin Flange √ √
6 Root of Flange √ √
7 Grease
Oozing/Warm box
√ √
B Air Brake Defects
1 DV replacement √ √
2 Angle cock
replacement
√ √
3 COAC safety Bkt.
Replacement
√ √
4 Dirt collector
replacement
√ √
5 Air hose
replacement
√ √
6 Air hose palm end
replacement
√ √
7 MU washer
replacement
√ √
8 Air hose carrier
replacement
√ √
9 Brake pipe √ √
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Present Scenario With proposed facilities
Sl
No.
Defects Examinati
on line
Sick line Examinatio
n line
Sick
yard
line
Sick
line
10 Piston stroke
adjustment
√ √
11 Auxilliary reservoir
Bkt. Replacement
√ √
12 Brake Cylinder
Leak
√ √
13 Branch Pipe Leak √ √
14 AR Tank Leak √ √
15 Common pipe
Bracket
√ √
C Bogie Defects
1 Brake block
replacement
√ √
2 Brake shoe
replacement
√ √
3 Brake shoe key
replacement
√ √
4 Split pin
replacement
√ √
5 End pull rod pin
hole adjustment
√ √
6 Push rod
replacement
√ √
7 Equalizing lever
replacement
√ √
8 Outer spring
replacement
√ √
9 Inner spring
replacement
√ √
10 EM pad √ √
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Present Scenario With proposed facilities
Sl
No.
Defects Examinati
on line
Sick line Examinatio
n line
Sick
yard
line
Sick
line
replacement
11 Brake beam pocket
liner replacement
√ √
12 Column plate √ √
13 CC pad √ √
14 Snubber Spring √ √
15 Snubber Wedge √ √
16 Slope Liner √ √
17 Side bearer Housing √ √
18 Side bearer Spring √ √
19 Adapter Cant √ √
20 Bottom spring plank √ √
D Brake Gear defects
1 SAB replacement √ √
2 SAB gear bush &
roller Bkt.
Replacement
√ √
3 Control rod
replacement
√ √
4 Load tie rod
replacement
√ √
5 Empty tie rod
replacement
√ √
6 Sleeve nut
replacement
√ √
7 L/E bkt & Handle
replacement
√ √
8 Short pull rod
replacement
√ √
9 End pull rod √ √
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Present Scenario With proposed facilities
Sl
No.
Defects Examinati
on line
Sick line Examinatio
n line
Sick
yard
line
Sick
line
replacement
10 Horizontal lever
safety Bkt.
Replacement
√ √
11 Brake Beam √ √
12 Low Bottom
(22WM)
√ √
E CBC /Draft Gear Defects
1 Knuckle changing √ √
2 Knuckle pin
changing
√ √
3 Knuckle pin APD √ √
4 Lock lift assembly
replacement
√ √
5 Lock replacement √ √
6 Operating handle
replacement
√ √
7 Bearing Pease
replacement
√ √
8 Stricker casting
wear plate
replacement
√ √
9 Shank wear plate
replacement
√ √
10 Draft Gear √ √
11 CBC Coupler Body √ √
12 Yoke √ √
13 Yoke Pin Support
Plate Rivets
√ √
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Present Scenario With proposed facilities
Sl
No.
Defects Examinati
on line
Sick line Examinatio
n line
Sick
yard
line
Sick
line
F Under Frame & Body Defects
1 Door fitting
replacement (minor)
√ √
2 Door fitting
replacement (major)
√ √
3 Hand Brake wheel
repair (steering
handle replacement)
√ √
4 Hand Brake rod
system
√ √
5 Foot step
replacement
√ √
6 Side stanchions √ √* √
7 Under frame
channel
√ √* √
8 Floor √ √ # √* √
9 Body √ √ # √* √
10 Door √ √ #
11 Top Pivot √ √
#. Repair of very minor nature
* Repair of medium nature.
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Annexure-III
Infrastructure facilities including M&P for CC rake Examination Yards
Description
Recommended Requirement
Trains examined per day
(average)
5-10 rakes per day
(A) INFRASTRUCTURE
1. Total lines required 2 Lines for examinations and one line for sick wagon and
one line for fit wagon and two lines for shunting and
traffic use.
2. Center to center
distance between two
lines
7.5 m centre to centre distance to be provided between
two lines for enabling proper examination and assure staff
safety from movements & for material movements.
3. Flooring in yard The complete area of examination yard i.e. 30 x 750 meter
will be provided with abrasion resistance granolithic
concrete flooring and ballast less embedded track, to ease
movement of vehicles.
4. Covered shed
The complete area of examination yard i.e. 30 x 720 meter
will be provided with covered shed.
5. Paved road for truck
movement.
Five meter wide paved road connection to Municipal road
from both ends of the yard.
6. Length of line Rake length plus fouling mark i.e. approx. 750 meter.
7. Supervisors Room One room of size 5mx7m.
8. Computer room One room of size 10mx7m
9. Staff room One room of 6mx10m at each end.
10. Rolling in/out huts One no. (3mx3m) at each end with spot light.
11. Field store + Tool room Should be the size of 10mx12m
12. Compressor Room 6mx8m room for each compressor.
13. DG room 6mx8m room for DG set
14. Vehicle parking room 15m x 7m
15. Yard control room 5m x 7m
16. Battery charging room
As per requirement depending on the number and usage of
material movement equipment.
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(B) LIGHTING
1. Tower light with
adequate height around
covered shed & spare
lines
Four tower lights (20 meter height) per examination yards.
2. Heavy-duty portable
rechargeable torches.
6 nos.
3. LED head light One per staff + 50 % spare
4. Overhead light Metal halide lamps OR LED Lamps
Details as per Annexure-VIII-A
(C) MACHINERY AND PLANT
1. Shunting engine 01 no
2. EOT crane with
pendant and remote
control facility
07 nos (If proposed)
3. Welding Plant
(portable)
06 nos
Details as per Annexure-VIII-C
4. Rail cum road vehicle
(capacity to haul 30
empty wagons)
01 no (If proposed)
5. Arc welding set
(Mounted on trolley)
Two nos.
Details as per Annexure-VIII-C
6. DG set 250 KVA (for
compressor, light &
welding)
One nos
7. DG set 500 KVA (for
cranes)
One no. (If proposed)
8. Electric/DSL
Compressor
(500 CFM) (Required
for brake power testing
of air brake train)
One no.
9. Gas cutting set 1 per examination batch
10. Protective clothing
with Helmet & Gloves
As per requirement
11. Welding Apron &
welding glass
As per requirement
12. Rake Test Rig One per line & one standby
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13. Hydraulic Jacks for
wagon lifting, Bolster
spring changing, Side
Bearer Spring changing
for HA and CBC wear
plate changing.
5 Jacks each of 10 Tons, 20 Tons and 25 Tons.
14. MUV (Four wheeled
Tata Ace truck )
02 per line
15. Staff van 2 per yard
16. Pick up van (for
movement from
outside)
2 per yard
17. Truck 02
18. Lister truck 4 nos.
19. Road mobile crane
(15 Ton capacity)
One no.
20. Hydraulic CBC lifting
crane (2 T capacity)
01
Details as per Annexure-III-A
21. Hand trolley 1 per line
22. Mobile (wheeled)
platforms to attend
doors etc
1 per line
23. Portable drill machine
12 mm
As per requirement.
24. Bending machine Not required One per yard
(D) MISCELLANEOUS
1. Storage rack with
pigeon holes
As per requirement
2. Rack with Locker One locker per staff
3. Rack with Locker One locker per staff
4. Plain paper fax with
P&T line
One per depot
5. Laptop As per requirement
6. Walkie Talkie set/
Mobile phone
25 nos
7. Railway Telephone As per requirement
8. P&T Telephone One per depot
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9. Computer, with printer,
Scanner, UPS with
preloaded software &
modem.
03 no.
10. C&W Office furniture As per requirement
11. Railnet Connection/
(Internet Connection if
Railnet is not available)
As per requirement
12. Xerox Machine for
printing, copying with
stabilizer
One per depot
13. PA system One per yard
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Annexure-III-A
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Annexure-III-B
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Annexure-III-C
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Annexure-III-D
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Annexure IV
The diagnostic systems of Northern Railway at TKD yard :
1. Way Side Data Collection Systems: are proposed to be installed at entry
to and exit from TKD yard. The system shall be in the form of
modularized set of instrumented detectors. These equipment shall pick up
data of moving trains and using standard comparators identify defect
locations. Data collected from this system shall be analyzed at the central
location in the yard. Using Wheel Data Management system Solution
Software (WDMS) and through network this result shall be provided to
the forth coming train examination gang. The system shall be capable of
indicating the wheel condition and any part requiring replacement
beforehand.
2. Acoustic Bearing Detectors: This shall provide information about bearing
condition and notify bearing that have internal defects related to cup cone
or rollers and prevent axle boxes before they become hot. The system shall
have an automated alarm notification with self-diagnostics.
3. Low Hose Detectors: This equipment is for identification of hanging parts
affecting bearing performance. This shall have a non-contact measurement
system to identify low hanging parts. It shall employ infrared light curtains
to identify each hanging part by measuring the distance between the part
and top or rail. This shall give graphical display of hanging parts and
automated alarm notification.
4. Wheel Impact Load Detector: The equipment shall detect the condition
of wheel with respect to flat tyre, its magnitude and send audio-visual
alarm to the centralized control system, if the limits are more than the
prescribed. This will enable the maintenance staff to plan the wheel change
in advance.
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5. Weigh In Motion (WIM) with load imbalance and overload detection:
This shall be used in consumption with WILD and shall provide
information for overload or load imbalance conditions.
6. Wheel profile recording detector: This equipment shall be able to
measure the bogie parameters such as vertical & lateral forces, vertical and
lateral movement while the wagon is in motion and shall be able to guide
the maintenance staff about the bogie condition with respect to the laid
down maintenance standards.
7. Machine vision equipments consisting of brake equipment monitor:
This system shall measure and monitor the brake blocks, especially its
wear.
8. Yard Center Database Integration: There shall be central control
integrated system for linking all performance monitoring system at the
TKD yard center in the wheel data management system (WDMS). The
information shall be displayed in a useable format for maintenance
personnel and management. It will include a web based interface and
integrate all detectors in the wayside detector system.
9. In-situ Wheel Changing: Mobile hydraulic jacks with wheel changing
facility –the equipments will be hydraulically operated and able to lift the
loaded wagons to a height so that the wheels can be taken out axially
instead of rolling out on the track. Adequate safeguards for fail safe
operation shall be available for operation safety. System shall be capable
of handling loaded wagons. Suitable forklifts trucks to transport wheels
from a central location shall be provided.
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Annexure –V-A
Trial Conducted at NKJ yard
[ As per CAMTECH Report No. CAMTECH/2008/M/W/Infra/1.0 Jan-2008 ]
Sl.no. Activity Time
taken
1 Attaching of diesel engine in front of incoming AC loco,
taking line block, checking of the load by C&W staff,
attention to minor repairs and brake testing, chalk
marking of wagons requiring detachment.
1’. 0.0”
2 Releasing line block and Pulling the rake to ROH shed 0 ‘ 15”.
3 Total time for bringing detachable wagons under position
of EOT cranes
0’54”
4 Creation of gap between individual wagons 0’38”
5 Time taken for detaching/ replacement of 13 wagons 1’44”
6 Recoupling of load, pulling the load ahead, detaching
diesel engine, creation of air pressure and despatch of
load
32 “
7 Total time taken 5’.03”
It can be seen from the table in para 7 that replacement of one sick wagon by a
fit wagon takes 8 minutes (average).
There was a substantial avoidable detention in this trial scheme due to limited
length (100 meters) of ROH shed and limited number of EOT cranes (2
numbers) and their limited capacity (15 T).
If entire rake is placed at one go inside the covered shed of 720 meters, the
required gaps can be created earlier and there would be a saving of 54 minutes.
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Annexure –V-B
Trial Conducted at PP yard Bhilai
[ As per CAMTECH Report No. CAMTECH/2008/M/W/Infra/1.0 Jan-2008 ]
(A trial was conducted at Bhilai yard to see total time taken from placement to ready per train )
Placement of
empty rake
for
examination
Issue of T-415
(5 minutes)
Examination
(1 hours)
Creating gap
(20 minutes)
Lifting of 10
detachable wagons
(ROH+POH+Sick)
and placement of fit
wagons (1 hours)
Repair on remaining wagons including
pipe connection etc.(1 hours)
* This activity will run in parallel to
creation of gap and lifting of wagons
Final amalgamation
of the train and
signing of BPC
etc.(10 minutes)
Average total time taken from placement to
ready per train is 2:35 hrs.
* After placement of rake, C&W staff will examine all the wagons and they will mark sick those
wagons, for which repair time is mote than 00:10 hrs. Fit wagons will be kept ready at the
adjacent spare line. The shunting engine will create gap in between sick wagons for shifting them
in adjacent spare line by Goliath crane. During shifting operation of the detachable wagons from
service line to spare line, the shunting loco will be sent for picking up fit wagons and shunt them
over the examination line. After completion of shifting of the wagons, the fit wagons will be
pushed for attaching as well as gaps will be closed.
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Annexure V-C
The flow chart indicating the sequence of activities :
(Based on trial conducted at NKJ yard to see total time taken from placement to ready per train
)
Arrival of train in yard
Diesel engine attaching,
releasing of rake, placement
in the examination yard
(30 min.)
Examination
(1 hours)
Creating gap
(30 minutes)
Lifting of detachable wagons
(ROH+POH+Sick) and
placement of fit wagons (1 hrs )
Repair on remaining wagons including pipe
connection etc.(1 hours)
* This activity will run in parallel to creation of gap
and lifting of wagons
Closing of gap, coupling of
wagons, connection of air
hoses
(30 minutes)
Detaching diesel engines, creation of air
pressure, continuity test, issue of BPC and
dispatch of train ( 45 minutes)
* After placement of rake, C&W staff will examine all the wagons and they will mark sick those
wagons, for which repair time is more than 00:10 hrs. Fit wagons will be kept ready at the adjacent
spare line. The shunting engine will create gap in between sick wagons for shifting them in adjacent
spare line by EOT crane. During shifting operation of the detachable wagons from service line to
spare line, the shunting loco will be sent for picking up fit wagons and shunt them over the
examination line. After completion of shifting of the wagons, the fit wagons will be pushed for
attaching as well as gaps will be closed.
*The total time inclusive of time taken in bringing the rake from reception yard to examination yard
and taking in to account bunching of rake is 5 hrs.
*The examination line will be occupied for 3.45 hrs.
Average total time taken from placement to ready per train is (4.15 hrs)
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Annexure-VI-A
Approx. Cost break-up for proposed facilities
Sr.
No.
Item Approx.Cost
in Rs
1. Abrasion resistance granolithic concrete floor
22500 sq mts. inside 720 mts x 30 mts shed.
1.7 Cr.
2. Shed 720 mts x 30 mts @ of Rs 14,500 per sq
meter.
31.32 Cr.
3. 7 EOT cranes of 30 T capacity @ 0.75 Cr. 5.25 Cr.
4. Shed illumination and power supply 2 Cr.
5. Yard alteration 2 Cr.
6. Sick line extension and upgradation 2.5 Cr.
7. Other M&P 2 Cr.
TOTAL 46.77 Cr.
2 R & D lines and 720 mts x 30 mts shed complex will be sufficient for
examination upto 10 rakes per day on an average.
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Present scenario ( for 10 rakes/day examination)
A. Average detention per rake =
17.10 hrs.*
B. Total rake hrs spent from arrival to departure =171.40 hrs
C. Rake days locked in yard (171.4/24) = 7.15
Future scenario
A. Detention per rake = 5 hrs.
B. Total rake hrs spent on account of examination= 50 hrs
(Arrival to departure)
C. Rake days locked in yard (50/24) = 2.08
Monetary Savings (In terms of cost of wagon)
D. Cost of wagon = 18.5 lacs
E. Cost of one rake = 58x18.5 = 1073 lacs
NET SAVING OF RAKES WILL BE 7.15-2.08 = 5.07 RAKES PER DAY
Savings in terms of rake cost = 5.07x1073 = 5440 lacs
= 54.40 Crores
(monetary saving)
I. The net earnings (excluding haulage costs) per wagon hour is
Rs.316/-
Net annual additional earnings due to recommended pattern
= Earning/wagon x No. of wagons per rake x no. of hours/year
= 316 x 58 x 365 x 24
= 16.05 Crores
Hence net annual savings due to proposed facilities
= Net saving of rakes x net earning per rake-Addl operating cost
= Rs.(5.07 x 16.05 ) – 1.43
= Rs. 79.95 Crores
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(for existing efficient yards)
Present scenario ( for 10 rakes examination per day)
B. Average detention per rake =
9.30 hrs.
B. Total rake hrs spent from arrival to departure = 93 hrs
C. Rake days locked in yard (93/24) = 3.875
Future scenario
C. Detention per rake = 5 hrs.
D. Total rake hrs spent on examination ( AR_DP)= 50 hrs
C. Rake days locked in yard (60/24) = 2.08
NET SAVING OF RAKES WILL BE 3.875 - 2.08 = 1.795 RAKES PER DAY
Monetary Savings (In terms of cost of wagon)
D. Cost of wagon = 18.5 lacs
E. Cost of one rake = 58x18.5 = 1073 lacs
Savings in terms of rake cost = 1.795x1073 = 1926 lacs
= 19.26 Crores
Net earnings per rake
= 16.05 Crores
Hence net annual savings due to proposed facilities
= Net saving of rakes x net earning per rake – Addl.operating cost
= Rs.(1.795 x 16.05 ) – 1.43
= Rs. 27.37 Crores
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Annexure-VI-B
Savings and advantages of the proposed facilities for
a model yard handling 10 rakes per day
[ As per CAMTECH Report No. CAMTECH/2008/M/W/Infra/1.0 Jan-2008 ]
Present scenario
C. No. of rakes examined per day = 10
D. Average detention per rake = 17.10 hrs.*
(* all India average based on sample figures of Oct.07)
C. Total rake hrs spent from arrival to departure =171.40 hrs
D. Rake days locked in yard (171.4/24) = 7.15
Future scenario
E. Rake examined per day = 10
F. Detention per rake = 5 hrs.
G. Total rake hrs spent on account of examination= 50 hrs
(Arrival to departure)
D. Rake days locked in yard (60/24) = 2.08
Note : 1. There will be no change in detachment due to ROH/POH.
2. There will be increase in detachment due to sick marking. But most
of these sick wagons will be made fit much faster in the new
system due to their attention under better working conditions and
faster placement in sick-lines. There will be no increase in wagon
hrs. lost in main sick line.
Net Saving of rakes will be 7.15- 2.5 = 4.65 rakes per day.
Monetary Savings
I. As per Traffic Accounts figures of SC Rly., the net earnings
(excluding haulage costs) per wagon hour is Rs.316/-.
Hence net annual additional earnings per rake saved due to
recommended pattern
= Earning/wagon x No. of wagons per rake x no. of hours/year
= 316 x 58 x 365 x 24
= 16.05 Crores
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Hence net annual savings due to proposed facilities
= Net saving of rakes x net earning per rake
= Rs.(4.65 x 16.05 )
= Rs. 74.63 Crores
II. Shunting in yard will be reduced with resultant saving in
manpower and rake availability.
III. Productivity of C&W staff will improve, as they will work under
covered shed with full illumination round the clock, all seasons in a
year.
Average earning capacity of wagon (Traffic Costing Cell, SC Rly.)
S.No. Details BCN BOXN
1 Avg. Wagon Km per Wagon day on line. (ASS-24 of 2003-04). 229.6 229.6
2 Avg. Wagon Km per one hr. (item (I) 24) 9.57 9.57
3 Carrying Capacity of Wagon in Tonnes. 55.7 58.81
4 NTKMs for one hour. (Item 2*item 3) 532.66 562.62
5 Commodity for loading Cemt.fert. Coal & I/ore
6 Avg. earnings per NTKM in Paise. (ASS.13 of 203-04) 82.1 72.4
7 Earning for NTKMs Lost (Item 4*item 6) per hr. 437 407
8 Cost of haulage per WKM. (ASS.15 of 2003-04)in paise. 540.74 540.74
9 Cost of hauling a wagon per Hr. 129 129
10 Dependent Cost @78.5%. 102 102
11 Net earning/opportunity Cost per Hr. (per wagon) (item 7-item10) 336 306
12 Net earning/opportunity Cost per Hr.escalated to 2004-05. Rs. 349 316
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Annexure-VII
Specification of Abrasion Resistance Granolithic Concrete flooring
ITEM-I
50 mm thick abrasion resistance granolithic concrete floor topping 1:1:2 (cement. fine
aggregate, coarse aggregate as per ISI 5491 laid monolithically or separately on
hardened base concrete metallic materials for high abrasion resistance in the top 15
thick layer only.
Without in any way restricting of modifying the provision of the general condition of
contract in that regard the rates for the above items of work shall be inclusive of all
costs of the following elements.
1. The work of granolithic concrete floor topping 1:1:2 (cement. fine aggregate.
coarse aggregate) will be carried out as per the relevant I.S. Codes, Railway's
specification of material and specification as applicable for plain, cement concrete,
RCC. In addition to this the IS Code 2571 of 1970 and 5491 (latest) will also be
referred for guidance.
2. The bays/floor panels layout for complete floor area will be drawn with correct
level and size as per the direction of Engineer-In charge. The screed strips will be
provided for granolithic as well as for base floor with all material/arrangements to
ensure smooth joints/corner of panels.
(a) Providing all shuttering, centering; staging, screed plates, as require for the
execution of the work.
(b) Mixing, transporting, lifting, placing, vibrating and testing of concrete in all
conditions, location and conforming to the relevant standard specification/ or
IS specification as appropriate.
(c) All lead including crossing of roads, trenches, culvert, pipe line or any other
existing feature at work site.
(d) All costs of contractor's labour, material consumables to plant and
machineries etc. complete in all respect including compaction
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equipment/surface vibrator for execution of work. .
3. The wooden float will be used to render the surface even and in level. The surface
shall be tested with a straightedge and mason's spirit level to detect any undulation in
the surface.
4. The size of panels, location of expansion/contraction joint will be pre
decided/finalized and work will be carried out in a planned manner and procedure as
approved by Engineer in-charge /representative.
5. The concrete mix of 1:1:2 as specified in item for ingredients will be taken as 1
cement, 1 fine aggregate and 2 part of coarse aggregate by volume. The cement
content for 50 mm thick granolithic concrete for 1 m2 of area will be 0.56 bags
(i.e.11.2 bags of cement for one m3 of concrete). The water cement ratio will be
within 0.4.
6. The granolithic layer will be laid monolithically within 2 to 3 hours of laying of
base concrete preferable within half an hour. The sequence of casting of granolithic
layer will be monitored with care full supervision under the guidance of Engineer
incharge/representative.
7. No concreting will be allowed without complete preparation of base concrete, the
surface of base concrete below granolithic be kept rough to have adequate bond.
8. The item rate includes testing of all materials as per relevant IS code specification
and concrete cubes testing for concrete. The required equipment for field tests and
arrangements shall be made as per direction of Engineer in charge.
ITEM -II
Providing and laying 20 mm thick granolithic concrete floor topping with M35/10
immediately after casting base concrete.
Without in any way restricting of modifying the provision of the general condition of
contract in that regard the rates for the above items of work shall be inclusive of all
costs of the following elements.
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(a) Formulating a design mix of the required strength in the number specified in the
relevant standard specification and/or IS specification as appropriate.
(b) Providing all shuttering, centering, staging, screed plates, as require for the
execution of the work.
(c) Providing and fixing to correct line level, size and shape, shuttering of steel
plates welded on steel framed panels and or approved quality ply wood panels
fixed with counter sunk screws on steel/wooden framed panes of a design, material
and construction to the satisfaction and acceptance of the Engineer or his
representative. The fixing of shuttering/screed plates being done in a manner to
obtain leak proof joints in the panels to prevent slurry leakage during placing or
compacting of the concrete by Vibration or trawling the concrete.
(d) Mixing, transporting, lifting, placing, vibrating and testing of concrete in all
conditions, location and conforming to the relevant standard specification / or IS
specification as appropriate Including testing of material for concrete and concrete
cubes.
(e) All lead including crossing of roads, trenches, culvert, pipe line or any other
existing feature at work site.
(f) All costs of contractor's labour, materials, consumables to plant and machineries
etc. complete in all respect for execution of work.
(g) The rates are inclusive of provision of all type of joints expansion, contraction
& construction joints. The dowel bars as per requirement will be paid under
separate steel items. The other work and material required to provide joints, cutter,
binding, placing and provision of specified joint in inclusive as approved by
Engineer In charge.
(h) The arrangement for adequate curing of concrete as required and directed by
Engineer in charge/ representative will be made. Any deficiency in curing will
result the rejection of work and full recovery for any deficiency noted during work
or afterwards. The deficient level, finishing or poor compaction will result full
rejection of deficient panel of flooring.
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Annexure-VIII
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Annexure-VIII-A
LIGHTING ARRANGEMENT FOR CC RAKE EXAMINATION YARDS
I. OVERHEAD LIGHTING
For lighting over general shed area
Illumination required : 100 – 150 lux
Mounting : Overhead hanging from covered shed structure
BLENDING OF LIGHTS
Metal Halide + blending with alternate fitting of T-5 tube light in each row
(For quick recovery of lights after power failure)
SPECIFICATION FOR 400W METAL HALIDE LIGHT FITTING:
Specification for light fitting luminaire shall be as given below:
Voltage : 230V AC 1, 50Hz
Lamp : 400 watts Metal Halide Lamp
Lamp type : Single ended clear elliptical Metal Halide lamp
Lamp base : E - 40.
Luminaire : Integral side mounted high bay luminaire
Lamp holder base : GES(E40), skirted porcelain.
Reflector
: Electrochemically brightened, high purity anodized
aluminium parabolic reflector.
Control gear
: Heavy duty copper wound ballast, ignitor, and power factor
correction capacitor suitable for 400 watt metal halide lamp.
The control gear cover shall be swung open for easy
maintenance.
Earthing terminal : Suitable for 14 SWG earthing wire.
Mains connector : 2 way 10 amps G.F.P. mains connector suitable for 4 sq. mm
incoming cable.
Installation : 18 mm ID Eye bolt with adjustable mounting plate for well
aligned suspension.
Wiring : All accessories of luminaire shall be prewired up to terminal
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block.
Tightness level : For control gear compartment IP 43.
IS : Luminaire shall confirm IS: 10322.
SPECIFICATION FOR LIGHT FITTING (for 4 x 54 W T-5 Highbay
Fittings):
Voltage : 230V AC 1, 50Hz
Lamp : 54 Watt x 4, T-5 energy efficient fluorescent Lamps
Energy Efficient High bay fitting made of Aluminium body, consisting with 4
Nos. separate Electronic ballast operative in 130V. 300V THD less than 10%
having power factor more than 0.95, suitable for 4 x 54W T-5 lamps system
complete with lamp, provided with suitable hanging arrangement at 12 mtr.
height.
Dimension : 600 x 1200 x 100 (Alternate to 400W MH lamps)
LIGHT FITTING CONFIGURATION
(Refer Drg. No. IRCAMTECH.GWL.EL.Wagon yard 1)
Overhead light fittings should be located at the roof structure of the
shed between examination lines.
Distance between the two fittings in a row along the shed length shall
be 12.0 metres.
Light fittings configuration between two rows shall be planned in
zigzag manner as shown in Drg. No.IRCAMTECH.GWL.EL.Wagon
yard-1.
SUPPLY AND CONTROL ARRANGEMENT
Overhead 3-phase 4-wire system laid with suitable brackets and insulators
along the shed structure under the roof.
Wiring:
3-phase 4-wire system, single core cable of suitable size PVC insulated 650/
1100 V aluminium conductor, unsheathed, unarmoured confirming to IS: 1554
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(Part I). Wiring shall run on suitable brackets mounted on shed structure with
reel insulators.
Overhead 4 wire, wiring shall be connected through a suitable size 3.5 core
650/ 1100V aluminium conductor, PVC insulated and sheathed, armoured
cable confirming to IS: 1554 (Part I) from MCBs. This cable should be
supported on suitable wooden brackets fitted on sheds coloumn structures.
Switch Gears:
Each row of light fittings should be supplied through a suitable rating. TPIC
switch and individual phase should be controlled by a suitable rating single
pole MCB.
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Annexure-VIII-B
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Annexure-VIII-C
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Annexure-VIII-D
Proposed Welding Transformer (Portable)
Transweld 202 or latest
A 220V Single Phase Welding Transformer
suitable for 2.5 mm, 3.15 mm & 4.00 mm
electrodes, yet ultimately portable - Transweld
202. It simply means that you get the value
for your money at the instant of buying the
machine itself. With ESAB’s expertise and
assurance, the confidence and quality of
performance comes packed with the machine.
Features
220V, portable and compact welding transformer
2.5 mm, 3.15 mm & 4.00 mm electrodes can be used
Infinitely variable hand welding current setting
Protection against overloading
Manufactured in an ISO 9001 certified factory
Class "H" Insulation
Description Transweld 202
Input Voltage 220V, 50 Hz, 1 Phase
Welding Current Range 60 - 200 Amps
Dimension (L x W x H) mm 495 x 345 x 410
Weight 43 Kgs
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Annexure-VIII-E
Proposed Welding Transformer
Transweld 400 - Air cooled welding transformer or latest
ESAB Transweld 400 is a 400 Amp Manual
Arc Welding Transformer that combines unique functional and safety features.
Ensures excellent welding quality with economy. Its natural air-cooled ensures
non-stop performance even in the most
uncertain difficult conditions. Ideal for use at site or in a workshop.
Special Features
Natural air cooled machine ensures maximum safety
Current available in single range. Current indicator and current control
handle both on front panel
Robust and compact construction ability to withstand rough handling at
sites
Horizontal shunt core travel ensures precise setting after prolonged use
Class ‘H’ insulation provides longer coil life
Technical Specifications
Input
Supply Voltage 415V, 2 Lines of 3 Phases,
50Hz AC
Rated Input Current 63 Amps
Rated Input KVA 26 KVA
Output
Open Circuit Voltage (Maximum) 80 V
Range of Welding Current 80 - 400 Amps
Maximum Continuous Hand
Welding current at 60% duty cycle
(Rated welding current)
300 Amps
Type of welding current regulation Stepless
Type of cooling Natural Air Cooled
Net Weight (Approx). 115 Kgs
Approx. Dimension 600 x 410 x 720 mm
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Annexure-IX
MULTI - UTILITY VEHICLE
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Annexure X
CHECK LIST FOR CC FREIGHT EXAMINATION POINT
Railway :……………Type of stock : …………Type of attention : … … …
Division : ………….. Avg. no. of rakes examined: …………
Sl.
No.
Item Availability Remarks
Yes No
1. 7.5 m center to center distance
between two lines
2. Concrete path way
3. Paved road for truck movement.
4. Supervisors Room
5. Staff room
6. Rolling in/out huts
7. Field store + Tool room
8. Compressor Room
9. Exhauster room
10. Battery charging room
11. Tower light
12. Street light along examination lines
at two levels
13. Portable rechargeable light
14. Hand lamps
15. Welding line
16. Arc welding set
(Mounted on trolley)
17. Portable DG set
18. DG set 250 KVA (for compressor,
light & welding)
19. Electric Compressor
(500 CFM)
20. Diesel Compressor
(500 CFM)
21. Gas cutting set
22. Hyd. Cold cutting set/ Hand shears
23. Protective clothing with Helmet &
Gloves
24. Welding Apron & welding glass
25. Pneumatic pipe line (32mm dia.)
26. Rake Test Rig
27. Hydraulic Jacks
28. Wheel Barrow
29. Pick up van
30. Truck
31. Lister truck
32. Road mobile crane
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Sl.
No.
Item Availability Remarks
Yes No
33. Hand trolley
34. Portable drill machine 12 mm
35. Drill machine
36. Bending Machine
37. Fitter tool box
38. Pressure gauge test stand
39. Folding type portable wheel
diameter gauge
40. Wheel distance measuring gauge
41. CBC height gauge
42. Tyre defect gauge
43. Electronic device/ Infra red
thermometer for detecting warm
box
44. Electric operated hand tools i.e.
Grinder.
45. Pocket Jack (Hydraulic)
6 Tons capacity.
46. Hand tools
47. Storage rack with pigeon holes
48. Rack with Locker
49. Fax machine with P&T line
50. Walkie Talkie set/ Mobile phone
51. Railway Telephone
52. BSNL Telephone
53. Computer with printer, Scanner, UPS
with preloaded software & modem
54. C&W Office furniture
55. Railnet / Internet connection
56. Zerox Machine
57. First aid equipment
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CHECK LIST FOR SICKLINE OF EXAMINATION YARD
Railway :……………Type of stock : …………Type of attention : … … …
Division : ………….. Avg. no. of coaches attended : …………
Sl.
No.
Item Availability Remarks
Yes No
1. Covered Shed
2. SAB Repair Room
3. DV Test Room
4. Service Building
5. Computer Room
6. Store Room + Sub store
7. Machine Shop
8. Battery room for charging lister/
jumbo truck batteries
9. Compressor Room
10. SE/JE Room
11. Pit line
12. EOT Cranes 15t/ 5t
13. EOT Crane 10T / 3T
14. Road Crane 10T Capacity
15. Jib Crane 2.5T
16. Electrical Stationary Screw Air
Compressor With Air Receiver
(500CFM)/ Dsl compressor
17. Turn Table
18. Trestles
19. Hydraulic Pipe Bending Machine
20. Bench Drilling Machine
21. Heavy Duty Pedestal Grinder
Double Ended
22. Shearing Machine 6 mm x 2200
mm wide
23. Battery Charger
24. Weighing Machine 500 Kgs.(for
scrap disposal )
25. DG Set
26. Gas Cutting Equipment
27. Plasma Arc cutting machine for SS
wagons
28. Work Station for Bogie Repair
29. Welding Machines
30. MIG/TIG welding machine for SS
wagons
31. Winches
32. Bogie Manipulators
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Sl.
No.
Item Availability Remarks
Yes No
33. Pipe line for air 32 mm diameter
34. CO2 Welding Machine
35. Rail cum road vehicle
36. Fork Lifter 3 Ton
37. Truck 10 Ton Capacity
38. Tractor With Hydraulic Lifting
Machine & 3 Trolleys (Trailers)
39. Platform Truck 2 Ton
40. Light Store Vehicle
41. Hand Trolleys with Rubber Wheels
42. Water Cooler
43. Floor cleaning machine
44. Fitters Lockers
45. Fax With P&T Line
46. First Aid Equipment
47. Photocopier
48. VHF Sets/ Mobile phones
49. Storage Racks
50. Portable Hydraulic Riveter
51. Stores Bin
52. Portable Electric Grinders
53. CBC & Draft Gear Replacement
Equipment
54. SAB Test Bench
55. Hydraulic Jacks 15 Ton
56. Set of special spring spanners, Box
spanners, Torque spanners
57. Bottle jacks
58. Pneumatic/ Electrical hand tools
59. Gauges & Instruments
60. Single Wagon Test Rig
61. DV Test Stand
62. Hand Tools
63. Pneumatic Torque Wrench With
Sockets 1" to 2"
64. Ultrasonic leak detector for tank
wagons)
65. Pressure gauge dead weight tester
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Annexure XI
RECOMMENDED ILLUMINATION AS PER IS 3646 (PART 1): 1992
SL
No.
Type of work Relevant Clause
of specification
Recommende
d Illumination
Quality Class of
Direct Glare
Limitation
Remarks
1. Goods Yard Adapted from
Clause 23.8.1.5
5-20 - The level may depend on topography,
road conditions, drainage, vegetation,
shunting frequency and yard capacity.
2. Entrance of Yard for
Rolling –in-Examination
Adapted from
Clause 7.7.1
300-500-700 1 As moving parts are examined, values
nearer upper limit should be selected.
3. Vacuum Exhauster/Air
Compressor Room
Adapted from
Clause 23.7.1.5
100-150-200 2
4. Store Adapted from
Clause 16.1
100-150-200 3
5. Wagon body lifting Shed 7.6.2 300-500-750 2 As moving parts are examined, values
nearer upper limit should be selected.
6. Machine Shop 7.3.2 300-500-750 2
7. Reclaim Section 7.3.1 200-300-500 3
8. Test Lab (D.V., SAB,
Hydraulic Jack etc.)
7.6.3 500-750-1000 1
9. Wheel shop
(i) General
(ii) On Wheel Lathe
7.1.1
7.3.3
200-300-500
500-750-1000
3
2
Local lighting may be used to
supplement the general lighting in
wheel lathe area.
NOTES
1. The above values are based on the IS Specification listed above, which may be referred for further details.
2. The number and quantity as well of type of bulbs may be decided based on the values for recommended illumination and quality class of
direct glare limitation.
3. These values are indicative and may need to be reviewed to suit local conditions prevailing.
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Suggestions received during Seminar at CAMTECH on 28.04.2017 SN Suggestions Suggested by Remarks by RLy
Board
01 Rake ID should be mentioned in revised BPC
formats.
STA/WCR, NKJ
02 Kilometres logging in BPC is not being done by
crew. Validity should be decided as per no. of
days only.
HPT/SWR,
SMP/WR,
NJP/NFR
STA/WCR
03 BOXN-HL wagon pillar are getting off from
bottom and wagon body is expanding.
HPT/SWR,
NKJ/WCR
04 Cases of Door eye bolt broken in BOXN-HL
wagon is more.
HPT/SWR,
NKJ/WCR
05 Space for 11 digit wagon number is insufficient in
BPC .
SDAH/ER,
SMP/WR,
STA/WCR
06 BPC Format should be bilingual. SDAH/ER,
SMP/WR,
STA/WCR
07 Striker casting may be condition basis in place of
must change in ROH.
SDAH/ER,
MGS/ECR,
BSP/SECR,
Gooty/SCR
08 Vertical liner for flat type centre pivot should be
must change in POH
MGS/ER
09 Clearance between pins and bushes (not more
than 1.5 mm) is difficult to check during
maintenance in sick line. (given in table 2.3 item
3.0 Bogie brake gear of Revised maintenance
manual for wagons)
NKJ/WCR
SMP/WR,
STA/WCR
10 Gradients for train examination yard should be
specified.
NKJ/WCR
SMP/WR,
STA/WCR
12 Standard Specifications/drawings for Bogie
manipulator, wheel turn table, Bogie assembly
line carrier and mobile work station required.
SMP/WR
STA/WCR
14 No. of revalidation of CC rake and validity of
revalidation to be specified.
ADI/WR
SMP/WR
STA/WCR
15 Railnet should be provided in all examination
yards.
ADI/WR
SMP/WR
STA/WCR
16 Concept of CC rake formation from off
ROH/POH wagons may be elaborated.
GIM/WR
SMP/WR
STA/WCR
17 In service safety tolerances should be provided,
some accidents cases findings are pending due to
non availability of safety tolerances in line with
P-Way.
SC/SCR
SMP/WR
STA/WCR
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SN Suggestions Suggested by Remarks by RLy
Board
18 Tolerances should be provided for trammelling
gauge dimensions & other bogie dimensions.
RDM/SCR,
BZA/SCR
20 Length of pit line for ROH repair need to be
increased for better examination of under gear
parts.
RDM/SCR
21 CC rakes are running after expiry of BPC validity
by traffic. It should be avoided.
KJGY/NR
SMP/WR
STA/WCR
22 Mostly BOXN wagons body and doors are being
damaged during loading/unloading.
NGY/NFR
SMP/WR
STA/WCR
23 Instruction for maintenance of bogies with LSD
and BMBS are required in field.
Gooty/SCR
SMP/WR
STA/WCR
24 Standardization for measuring heights of springs
(grouping) with the help of machine should be
done.
Gooty/SCR,
BZA/SCR
SMP/WR
STA/WCR
25 LED inspection lamp is better for examination. MGS/ECR,
NKJ/WCR
SMP/WR
STA/WCR
26 Both Diesel & Elect. Compressors are required in
CC Rake depot.
NKJ/WCR &
SMP/WR
27 LED hand held rechargeable torch is required for
CC rake examination
MGS/ECR,
GIM/WR
28 Covered shed is not required for examination
lines.
SMP/WR
STA/WCR
29 6 Nos. tower lights/high masts required for 750 m
length examination line.
MGS/ER,
NKJ/WCR &
KGJY/NR
30 One dedicated shunting Loco is required (under
control of operating Deptt.)
NKJ/WCR &
KGJY/NR
SMP/WR
STA/WCR
31 For rake testing, taping from air pressure line is
required at starting end and air pressure line is
required at only one line and taping to be
provided for other lines.
NKJ/WCR &
KGJY/NR
SMP/WR
STA/WCR
32 Total 03 Nos. welding plants are required one for
each line and two spare plants for breakdown.
MGS/ECR &
GIM/WR
33 01 no. MUV (multi utility vehicle)/yard is
required for material transportation.
NKJ/WCR,
SMP/WR
STA/WCR
34 01 no. staff van/yard is required for staff
transportation.
NKJ/WCR,
MGS/ECR
SMP/WR
STA/WCR
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SN Suggestions Suggested by Remarks by RLy
Board
35 01 no. Pickup van/yard is required for Depot. RTM/WR &
BSP/SECR
SMP/WR
STA/WCR
36 02 Nos. of truck also required for transportation
of store material.
SMP/WR &
MGS/ECR
SMP/WR
STA/WCR
37 01 Road mobile crane of 15 T capacity is required
in depot.
MGS/ECR
SMP/WR
STA/WCR
38 Portable drill machine and hand grinder are
required
MGS/ECR &
STA/WCR
SMP/WR
39 Pit is required for maintenance of wagon fitted
with BMBS and BVZI brake van & Tank wagon.
MGS/ECR &
BIA/SECR
SMP/WR
STA/WCR
40 WARS (Software for freight Depot) to be
developed in new version to meet present
requirement.
MGS/ECR &
STA/WCR
SMP/WR
41 No. of Hand trolley in depot may be decided as
per requirement of individual depot.
KGJY/NR &
SMP/WR
STA/WCR
42 OHE lines should not be provided over
maintenance lines but in many depots, OHE lines
are available over maintenance lines. There must
be a isolation facility to isolate OHE lines.
VSKP/ECoR &
NJP/NFR
SMP/WR
STA/WCR
------