DRAFT REPORT ON PRE-FABRICATED PITLINE …rdso.indianrailways.gov.in/works/uploads/File/Draft...guidance of Mechanical engineers involved in maintenance of Coaching stock. It covers

Government of India Ministry of Railways

DRAFT REPORT ON

PRE-FABRICATED PITLINE WITHOUT CATWALK WITH COACH WASHING PLANT

CAMTECH/2014/M/PWC/1.0 August – 2014

(For official use only)

PRE-FABRICATED PITLINE

WITHOUT CATWALK WITH

COACH WASHING PLANT

Preface

Railway Board has issued instructions vide letter No. 2007/MC/141/1 dated

12.03.14 to CAMTECH to prepare Pre-fabricated pit line for coaching depots to

facilitate maintenance staff in doing faster and quality maintenance schedule & to

minimise maintenance cost also. During meeting for “Review of IOH/ POH

periodicity of coaches and performance review of LHB coaches” held in Railway

Board on 06.03.2014, it is decided that Report should be prepared according to

requirement in line with DMRC and revision in M&Ps should also be done to have

full complement of tools/equipments & other machine plants.

This Report is prepared with the objective to provide informative technical details

on “Pre-Fabricated pit line without catwalk with coach washing plant” for the

guidance of Mechanical engineers involved in maintenance of Coaching stock. It

covers the constructional features of fabricated pit line, lay out drawing of pit line

without cat walk & with Automatic coach washing plant.

This Report does not supersede any existing instructions from Railway Board,

RDSO & Zonal Railways and the provisions of IRWM, BIS codes & reports on the

subject. This Report is not statutory and contents are only for the purpose of

guidance. Most of the data & information mentioned herein are available in DMRC

and Coaching Depots on IR.

We welcome any suggestions from our readers for further improvement.

CAMTECH/Gwalior (K.P.Yadav)

Date : 21.07.2014 Director/Mech.

Contents

S.N Description Page no.

1. Objectives 1

2. New design of pre-fabricated pit line without catwalk

and with ACWP (Automatic Coach Washing Plant) 1

3. Twin depth pit line 3

4. Modern equipments 3

5. Other facilities 3

6. Coaching Depot Layout 3

7. Data/details of layout of coaching complex 5

8. Features of maintenance bay 7

9. Features of maintenance bay

(pit line without catwalk with shed) 8

10. Features of maintenance bay

(pit line without catwalk without shed)

9

11. A view of pit line at DMRC on steel pillars: 10

12. Maintenance bay showing ramp, stairs & pillars: 11

13. Service room & space for vehicle & machinery: 12

14. Features of IOH depot (maintenance sick line): 13

15. Maintenance sick-line 14

16. Details of infrastructure facilities proposed for

primary maintenance depot holding 500 coaches

(100 AC + 400 Non AC)

15

17. Some modern equipments 24

18. Automated Wheel Diagnostic System (WDS) 24

19. Mobile lifting platform 27

20. Coach lifting system 28

21. Wheel changing system 29

22. Automatic in-motion train washing system (ACWP) 30

23. Layout and construction of automatic coach washing

plant 32

24. Process of coach cleaning and washing in different stages 35

25. Internal coach cleaning machine 39

26.

27.

28.

29.

30.

ISSUE OF CORRECTION SLIPS

The correction slips to be issued in future for this handbook will be

numbered as follows:

CAMTECH/2014/C/FOUNDATION/1.0/CS. # XX date ...………….......

Where “XX” is the serial number of the concerned correction slip

(starting from 01 onwards).

CORRECTION SLIPS ISSUED

Sr. No. of

C.Slip

Date of

issue

Page no. and Item No.

modified

Remarks

CAMTECH/2014/M/PWC/1.0 1

Draft Report on pre-fabricated pitline without catwalk with coach washing plant August - 2014

1.0 OBJECTIVES:

Railway Board vide their minutes of the meeting for “Review of IOH/ POH

periodicity of coaches and performance review of LHB coaches” held in

Railway Board on 06.03.2014, No. 2007/M©/141/1 dated 12.03.14 under

item “B” and S. No. 14 for performance review of LHB coaches and other

issues directed CAMTECH to evolve a design of pit line with pre-fab.

constructions for expeditious implementation of projects. In addition to this,

need to construct a catwalk should also be re examined as pit lines without

catwalks also have advantages of more open space, easy and speedy

construction and are economical as well.

2.0 NEW DESIGN OF PRE-FABRICATED PITLINE WITHOUT

CATWALK AND WITH ACWP (AUTOMATIC COACH WASHING

PLANT

Previously a 3Tier system for coach maintenance was adopted by Indian

Railway on the basis of recommendations made by CAMTECH and

approved by Railway Board vide their letter No. 95/M©/165/11 dated

09.08.1999. In three tier system, the provision of catwalk was made for

washing/ cleaning operation of coaches during maintenance. During

finalisation of report, the provision of automatic coach washing plants at

maintenance depot was examined but, at that time, Indian Railways were

still in the process of laying these plants at few locations. It was decided

that as Railways as become fully confident with their design, performance

and sources of supply and automatic plants get proven in service, the above

arrangement may be reviewed suitably in order to explore the possibility of

having pit lines without catwalks.

In catwalk less design, for changing destination boards and window glass

cleaning, adequate number of movable trolleys/forklifts with suitable

attachment may be required. The requirement of water pipeline for coach

washing may also be reviewed in such cases.

As discussed in 12th CMG at Guwahati & CME’s conference at Mumbai

and Shimla, it is felt by some of the Railways that the activities to be carried

out on a catwalk can be undertaken with the help of alternative means such

as mobile platforms, listers etc and therefore pit line design should be

without cat walk.

During the seminar at CAMTECH on 21.07.2014 on the issue, participants

were of the opinion that catwalk contributes little but only makes hindrance

in the free movement of man and material. Daylight is restricted and layout

makes clumsy. A new design of pit line without catwalk should, therefore,

be developed or Prefab casted catwalk with longer span may be provided.



ACWP has been considered necessary for outside cleaning of the coaches.

This will reduce the efforts and time taken at the pitline considerably. It

will also improve the quality of the cleaning of the coaches. This will

ensure reduction in water consumption and wetness in the pitline. It has

been noticed that coach washing plants which are in use on Indian Railways

are not working properly due to various reasons. It is, therefore, proposed

that a washing plant of a specification equivalent to one available at

DMRC/PA coaching depot should be provided.

A unified pitline for internal cleaning of coaches/examination and repair has

been considered in place of separate facilities for internal cleaning of

coaches and repair/examination of coaches. It has been noticed that if

separate facilities are provided, the time taken in shunting is 1-2 hours and

thus the cycle time increases considerably. The very purpose of this

exercise i.e. to reduce the maintenance time gets defeated. Further, since

ACWP has been provided, the coach washing will anyway be done at the

entry point of the pitline, therefore, spillage of water on pitline will be

reduced to a great extent. This will serve the purpose of keeping the pit dry

to a great extent.

2.1 Merits and Demerits of Catwalk

SN Disadvantages of Catwalk Advantages of without Catwalk

01 Clumsy lay out Less clumsy lay out

02 Day Light is restricted Plenty of daylight id available

03 Cross movement is also

restricted

Easy movement of maintenance

staff



3.0 Twin depth pit

In the existing pit, staff could not walk without bending. Therefore, to

avoid this difficulty, it has been proposed to provide twin pit. In this design

a pit of size 600 mm wide and 450 mm deep pit has been provided in centre

of the main pit for easy walking of the staff. This will also serve as drain to

the pit as a FRP/Metallic mesh has been provided as a covered on the deep

drain for this purpose.

4.0 Modern Equipments

To improve reliability, reduce maintenance time and to have state of art,

facilities for examination, repair and maintenance of coaches, following

modern equipment have been recommended:-

Automated Wheel Diagnostic System

Mobile Lifting Platform

Bogie/Car body lifting System

Waste removal system for Bio-Toilets/Vacuum Toilets

Automatic in-motion Train Washing System

Bogie turn table.

5.0 Other Facilities

Other facilities such as boundary wall, pliable road throughout the coaching

depot, concrete flooring, service rooms, proper lighting and their accessories

have also been proposed.

6.0 Layout

6.1. The coaching depot is planned for 26 coach length rake.

6.2 The coaching depot consists of

a) Automatic in-motion coach washing plant (ACWP)

b) Automated wheel diagnostic system (WDS)

c) Maintenance bay (Pit-line)

d) Maintenance Sickline (under covered shed)

e) Service rooms

f) Stabling line

g) Shunting neck



6.3 Sequence of operation

(a) Train entering into the coaching depot

(b) Outside train washing on automatic in motion coach washing plant

(c) Detection of wheel defect on automated wheel diagnostic system

(e) Placement of rake on maintenance bay for complete maintenance and

safety examination

(f) Pulling the rake in shunting neck

(g) Train going out of the coaching depot after complete maintenance

Ref: Sketch-01



7.0 Data/detail of layout of Coaching Complex

77..11 (a) Length of the Coaching Complex = 2104 m

(b) Width of the Coaching Complex = 120 m

77..22 (a) Thickness of boundary wall = 23 cm

(b) Height of boundary wall = 2 m

(c) Length of boundary wall = 4000 m

7.3 (a) Width of road = 5 m

(b) Length of road = 2285 m

7.4 (a) Total track length = 6 km

(b) Number of points and crossings = 9 sets

7.5 (a) Width of the maintenance bay = 14.49 m

(b) Length of the maintenance bay = 620 m

(c) Construction of the maintenance bay = as per drawing/detail

77..66 (a) Width of maintenance Sick line = 19.5 m

(b) Length of maintenance Sick line = 200 m

(c) Construction of maintenance Sick line = as per detail

7.7 (a) Width of Service rooms = 5m

(b) Construction of Service building = as per detail

7.8 (a) Width of compressor and exhauster rooms = 5m

(b) Length of compressor and exhauster rooms = 10 m

(c) Number of rooms = 2 nos.

7.9 (a) Width of sub-station rooms = 5 m

(b) Length of sub-station room =10 m

(c) Number of sub-station room= 2 nos

Ref: Sketch-01



Prep

ared

By

Sket

ch N

o. 1

CA

MTE

CH

/Gw

alio

r



8.0 Features of maintenance bay

8.1 Data/dimensions :

(a) Length of maintenance bay = 620 metres

(b) Width of maintenance bay = 14.49 metres

(c) Capacity = 2 rakes

8.2 The maintenance bay is meant for all safety checks, schedule and non

schedule maintenance of under gear and upper gear.

8.3. Main features of the maintenance bay are -

a. Broad and obstacle free pathways.

b. Under pit pathway below the rake/track.

c. Pit line on metallic (steel) pillars.

d. Ramp at both the sides to go from ground level to pathways.

e. Provision of stairs to go from ground level to pit pathway.

f. Provision of service rooms.

g. Provision of mobile lifting platform (for without catwalk).

h. Provision of compressed air pipe line.

i. Provision of overhead light.

j. Provision of under pit light.

k. Provision of 48V,110V, 230V ,440V cables and sockets

8.4 Other salient features:

a. The covered shed is having zig-zag placement of sufficient number of

transparent sheet for sufficient natural light during day time.

b. To make the pathways obstacle free cables for the sockets are running

underground.

c. The under pit light are located such that they come under each bogie

of each coach.

NB : 1. The sketch of maintenance bay does not have structural and

foundation design of load bearing items.

2. Hence the dimensions shown may require changes due to design

considerations.



9.0 Features of maintenance bay (pit-line without catwalk with shed)

9.1. Data/dimensions :




PIT LINE WITHOUT CAT-WALK

2500

960

e

325

960

C250

850

400

600

1250

4503000

a

40

25

d

3245

d d

1300785

2500

960

e

Prepared by CAMTECH Gwalior

Sketch No. 2

3245

d

b

2 m

a

5 m

Ground Level

3 m

Drain

Note : The pit line is proposed on steel pillars of 500x500 size with a clear space

of 1000 mm between the pillars. The detail drawing to be prepared by the

Zonal Railways based on actual site conditions and necessity of loco

movement.



10.0 Features of maintenance bay (pitline without catwalk without shed)

10.1. Data/dimensions :






11.0 A view of Pit line at DMRC on steel pillars:



12.0 Maintenance bay showing ramp, stairs & pillars:

Sket

ch N

o. 4

Prep

ared

By

CA

MT

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wal

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13.0 Service Room & Space for Vehicle & machinery:

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14.0 Features of IOH Depot (Maintenance Sick Line):

1. Data/dimensions :

(i) Length of maintenance sick line = 200 metres

(ii) Width of maintenance sick line = 19.5 metres

(iii) Capacity = 2 lines

2. The IOH Depot (maintenance sick line) is meant for attending the unfit

coaches and for attending higher maintenance schedules of the coaches.

3. Main features of the maintenance sick line are:

a. Provision of 04 coach length examination pit – one on each line.

b. Provision of wheel profile lathe.

c. Provision of bogie/coach lifting system.

d. Provision of equipments like coach lifting jacks, material carrier,

fork lifter, hoist, bogie turn table.

e. Provision of service rooms, store and vehicle parking space.

f. Provision of wheel parking.

g. Provision of covered shed.

h. Provisions of electrical fitting, light, fan etc and electric supply to all

fixed and portable machines and equipments

NB : 1) The sketch of maintenance sickline does not have structural and

foundation design of load bearing items.

2) Hence the dimensions shown may require minor changes due to

design considerations.

3) Big machineries like wheel lathe, coach lifting system etc should be

installed suitably.

Ref: Sketch No. 05 & 06



15.0 Maintenance Sick-line:

CAM

TECH

/Gwa

lior

Prep

ared

By

Sketc

h No.

6



16.0 DETAILS OF INFRASTRUCTURE FACILITIES PROPOSED FOR

PRIMARY MAINTENANCE DEPOT HOLDING 500 COACHES

(100 AC + 400 NON AC)

16.1. INFRASTRUCTURE & BUILDING

S.N. ITEM COACH

HOLDING

500(100 AC +

400 NON AC)

1. Covered shed (sick line ) 1

2. Maintenance lines with pit

(No. of lines X No. of coaches) 2 x 4

3. Linen store room, size 5 m x 10 m 2

4. Room for storing cleaning equipment, size 5 m x 10 m 1

5. Mech. Item repair room with test benches, size 5m x 8

m (DV, brake cylinder, CDTS etc) 4

6. Mechanical millwright room, size 5 m x 8 m 1

7. Computer room, size 5 m x 5 m 1

8. Battery room with battery beds, size 5m x 10m 2

9. Fans repair room, size 5 m x 10 m 1

10. Light fittings repair room, size 5m x 10m 1

11. Alternator/ regulator repair cum testing room, size 5m

x 10 m 2

12. Compressor repair room with AC cabin, size 5m x 5m 1

13. Switch gear test room with shelves and test benches/

work benches, size 5 m x 8 m 1

14. Motors repair room with shelves and test

benches/work benches, size 5 m x 8 m. 1

15. Simulator training room for RMPU, inverter & power

panel, size 5 m x 10 m. 1

16. Filter cleaning arrangements with blower & water

sump size 5m x 5m 1

17. Tool room with shelves & almirahs, size 5 m x 8 m. 2



S.N. ITEM COACH

HOLDING

500(100 AC +

400 NON AC)

18. Storing facility for Lube, HSD, Kerosene oil, size 5m

x 5m. 1

19. Storing facility for refrigerants, DA, Oxygen, Nitrogen

cylinders, size 5 m x 5 m. 1

20. Pantry equipment repair room, size 5 m x 5 m. 1

21. Depot Officer room (Gazetted) , size 5 m x 5 m. 1

22. Incharge/ Supervisors office , size 5 m x 5 m. 4

23. Establishment office, size 5 m x 10 m 1

24. PPIO office, size 5 m x 5 m. 1

25. Material management office, size 5 m x 5 m. 1

26. Main store with Unit Exchange Spares and material

storing facilities size 5 m x 10 m. 3

27. Shift/ Custody stores with material storage facilities,

size 5 m x 5 m. 2

28. Conference room of size 5 m x 10 m. 1

29. Staff room with lockers, size 5 m x 8 m. 2

30. Staff room for ladies size 5 m x 5 m 1

31. Electronic lab (AC) with all repair and testing

facilities, size 5 m x 5 m 1

32. Staff training room facilities including Multimedia

projector, LCDTV, video camera, DVD Handycam &

other modern teaching aids, size 5 m x 8 m.

1

33. Vehicle repair room, size 5 m x 8 m. 1

34. Staff Canteen of size 5 m x 20 m. 1



16.2 OTHER INFRASTRUCTURE

S.N. ITEM COACH

HOLDING

500(100 AC +

400 NON AC)

1. Scrap material space of adequate size 1

2. Scooter & cycle stand 1

3. Separate toilets for ladies & gents at suitable

locations

4

4. Garage for pickup van/ material van 2

16.3 MMAACCHHIINNEE && PPLLAANNTT ((MMeecchhaanniiccaall))

S.N. ITEM COACH

HOLDING

500(100 AC +

400 NON AC)

1. Automatic coach washing plant (ACWP) 1

2. Wheel diagnostic system (WDS) 1

3. Coach lifting system 1

4. Wheel profile lathe 1

5. Hydraulic lifting jack/Whiting Jacks 6

6. Welding plant (portable) Single phase 230 V 4

7. Welding plant (Stationary) 3 Ph. 440 V 2

8. Air compressor-350 cfm 2

9. EOT crane 5T in maintenance sick line 2

10. Floor scrubber 10

11. Dry & wet vacuum cleaner 10

12. Mobile jet cleaner 10

13. Drainage pump heavy duty 5HP (Muck pump

centrifugal) 2

14. Sewing machine 1

15. Portable pump 2

16. Gas welding-cutting set 4

17. Lathe machine, 1000mm between center complete 1



S.N. ITEM COACH

HOLDING

500(100 AC +

400 NON AC)

including spares and accessories with attachment

for precision grinding and tapering.

18. Bench vice 4

19. Medium sized electric motor driven pillar drilling

machine complete.

2

20. Heavy-duty motor driven pedestal grinder

complete.

2

21. Portable electric motor driven drill machine. 4

22. Portable electric motor driven grinder. 2

23. Electric motor driven Winching machine for

movement of coaches of suitable capacity

2

24. 46.7 Ltrs spare oxygen (7 m3 ) cylinders 4

25. 41 Ltrs spare Acetylene (5.5 m3 ) gas cylinders 4

26.

Hand tools for mechanical staff

As per

requirement

27. Maintenance staff tool boxes with tools. For each

technician

16.4 MACHINE & PLANT (Electrical)

S.N. ITEM COACH

HOLDING

500(100 AC +

400 NON AC)

1. Distilled water plant – preferably solar system, (in

ltrs per day) 2 x 100 lpd

2. Condenser cleaning tank 1

3. Hydraulic operated scissor – type platform truck of

1Tonne capacity.

4

4. Vacuum pump with gauges etc. 2

5. Battery charger sets 110V, 300A DC 3

6. Portable battery charger input 230 V single phase,

output 110V, 40A DC

2



S.N. ITEM COACH

HOLDING

500(100 AC +

400 NON AC)

7. Battery charging/ pre cooling sockets with

universal type connector

At each coach

length

8. Constant current constant voltage battery charger

upto 10 cells.

1


upto 12 cells

2


upto 56 cells.

2

11. Constant current discharger. 2

12. Battery analyzer 2

13. Air quality measurement facility 2

14. Dynamic balancing machine for balancing of fans,

shafts & alternator pulley

1

15. Hydraulic puller of 10T capacity 2

16. Escorting staff tool boxes with tools. (As per

RDSO)

For each

escorting staff

17. Maintenance staff tool boxes with tools. (As per

RDSO)

For each

technician

18. Motorised Megger 500, 1000V. 4

19. Refrigerant recovery plant. 1

20. Electronic weighing machine upto 15kg 2

21. Electronic weighing machine upto 50 kg 3

22. Electronic weighing machine upto 500 kg 1

23. Ordinary tool set for tool room (Torque wrenches,

special spanner, soldering iron, manual cable

crimping tool, hydraulic crimping tool, cable

stripper, cable cutter, pliers, screw drivers, line

tester, cell tester, test lamp, hammers, mallets,

riveting tool, punching tool)

15

24. Measuring tool set for tool room (dial indicators, 15



S.N. ITEM COACH

HOLDING

500(100 AC +

400 NON AC)

feeler gauge sets, vernier calipers, vernier

micrometers, torque wrench, depth gauges, screws

gauge, Go/No Go gauges, Hydrometer)

25. Special tools for AC for tool room (Refrigerant gas

leak detector, Tube cutters, pinch off tool flaring

tool, charging line, hand shut off valves,

combination gauge, air flow meter, Contact less

thermometer, LP gauge, HP gauge, tube bender,

lapping machine)

10

26. Electrical testing tools for tool room (Digital multi

meters, industrial grade AC & DC ammeter, digital

tongue tester, insulation megger tester, contact less

thermometer, digital thermometer, Anemometer,

hygrometer, lux meter)

15

27. Testing benches comprising following equipment

variable voltage supply AC & DC, transistor tester,

meter testing kit,

2

28. V-belt pre stretching machine (grading machine). 4

29. Portable electric motor driven blower 6

30. 46.7 Ltrs spare Nitrogen (7 m3 ) gas cylinders 4

31. Spare R-134a refrigerant cylinders 6

32. Digital dB. Meter (noise level indicator) 1

33. Oven for drying electrical machines etc. of suitable

size.

1

34. DG set, with canopy 415V of adequate capacity as

standby power supply

1

35. Shock pulse meter 3

36. Tachometer 1

37. Platform jack for handling alternators on the

coaches

2

38. Grease gun for lubricating equipments 1



16.5 TESTING FACILITIES (Electrical)

S.N. ITEM COACH

HOLDING

500(100 AC +

400 NON AC)

1. Pit mounted 25 kW AC test drive complete set (2

unit per set) for alternator and regulator testing.

1

2. Floor mounted 25 kW AC test drive complete set

with regenerative load testing for alternator and

regulator testing.

2

3. Test benches for testing relays & contactors with

contacts testing.

1

4. 1kW Portable motor drive set for testing alternator

and regulator.

3

5. Power supply analyzer, oscilloscope dual channel,

storage type

1

6. Surge comparison tester for testing windings of

motor

1

7. Inverter testing facility 1

8. Inverter card reading & repairing facilities 1

9. WRA/ Mono-block pump testing facility 1

10. Spring testing facility for testing of alternator spring 1

11. Test bench for repairing RRU, ERRU and

alternators

2

12. ERRU testing facility all make 1

16.6 TESTING FACILITIES (Mechanical)

S.N. ITEM COACH

HOLDING

500(100 AC +

400 NON AC)

1. Air brake rake test rig 2

2. Single car test rig (SCTR) 2

3. Water tank test rig 1

4. Ultrasonic testing apparatus 1



5. DV test bench 1

6. SAB test bench 1

7. Test bench for CDTS/Bio-Toilet 1

16.7 MATERIAL HANDLING EQUIPMENTS

S.N. ITEM COACH

HOLDING

500(100 AC + 400

NON AC)

1. Fork lifter 3T 2

2. Fork lifter 1.5T 2

3. Lister 1.5T 6

4. Mobile lifting platform 10

5. Hydraulic pallet truck 01T capacity 4

6. Lorry truck 1

7. Pick up Van 2

8. Push type/ Hand trolley 500 kg 6

9. Material van 2



16.8 SAFETY EQUIPMENTS

S.N. ITEM COACH

HOLDING

500(100 SG AC +

400 NON AC)

1. All workmen safety equipments such as industrial

helmets, hand gloves, industrial shoes, masks,

minor lamp etc.

As per

requirement

2. Fire extinguishers, water hydrants, sand buckets

with stand

As per

requirement

3. Safety belts As per

requirement

4. FFiirrsstt aaiidd bbooxxeess As per

requirement

16.9 ADDITIONAL

S.N. ITEM COACH

HOLDING

500(100 AC +

400 NON AC)

1. Computer (PC) with printers with LAN facility. As per

requirement

2. Fax Machine 1

3. Zerox Machine 2

4. Walkie talkie sets/ Mobile sets/P &T phones/

intercom and other communication facilities

As per

requirement

5. Water Cooler As per

requirement

6.

Storage racks, almirah, locker, furniture etc

As per

requirement

7.

Bins, container etc

As per

requirement

NOTE: Facilities for the items which are likely to be offloaded to trade

should be provided judiciously to avoid wastage of resources.



17.0 SOME MODERN EQUIPMENTS

a. Automated Wheel Diagnostic System (WDS)

b. Automatic in motion Train Washing System

c. Mobile Lifting Platform

d. Bogie/Car body lifting system

e. Under floor bogie repair hoist

f. Turn table

g. Waste removal system for Bio-Toilet

18.0 Automated Wheel Diagnostic System

A- DDeessccrriippttiioonn:: Wheel Diagnostic System is a fully automatic and in

motion inspection and testing unit for the diagnosis of wheels of

vehicles in operation.

B- Wheel diagnostic system aims at the following types of diagnostic

work :-

a. Vehicle/wheel set identification

b. Measurement of roundness of wheel and detection of value of

out of roundness

c. Detection and measurement of flat spots

d. Measurement of tread diameter and detection of overshooting

of operational tolerances

e. Measurement of wheel profile and detection of overshooting of

operational tolerances

f. Detection of cracks

Probable source: 1. Hegenscheidt –MFD GmbH & Co Kg

P.O. Box 1652-D-41806 Erkelenz

Website : www.hegenscheidt-mfd.de

Fax- 0049(0) 2431 86 470

Indian agent : M/s VGI Power Systems(P) Ltd.

16-A, Palam Marg, Vasant Vihar

New Delhi-110057

Contact person (India): 1. Mr. Jaspreet Singh

Mobile no. 09810421620

2. SAB Wabco

Cost : Rs.5.0 Crores

http://www.hegenscheidt-mfd.de/



18.1 Technology:

A. Wheel diameter/wheel profile measurement (laser based)

The moment wheel passes over the rail, a beam of light is passed on to

the wheel from under it. The emerging rays are received by a receiver

and fed to a computer which evaluates the inputs. By using Opto-

electrical equipments and high resolution digital cameras and

computers which are capable of accurately processing the digital

data, the wheel profile measurement can be performed.

BB.. DDeetteeccttiioonn ooff ffllaatt aarreeaass && oouutt ooff rroouunndd

Along a stretch of track equal to the circumference of the wheel, distance

between the track and the wheel crown is continuously measured

electronically and evaluated by a computer. The flat areas are detected by

the variations of height between track and the wheel crown. The difference

between largest and smallest diameter will give the measurement of

out of round.

CC.. CCrraacckk ddeetteeccttiioonn

Two ultrasonic scanning heads each are integrated in the left and right rail

of the track, when a wheel passes through the scanning heads, this transmits

ultrasonic impulse for the detection of the cracks on the tread surfaces.

By providing wheel diagnostic system, it will pre-warn the condition of

wheels. This will help in -

Average planning of wheel profiling and wheel change.

Improved safety and reliability

Improved wheel life.

Reduction in examination time and manpower.

Based on above benefits the provision of wheel diagnostic system is justified.

(Photograph on next page)



18.2 Photograph of Wheel Diagnostic System

18.3 Layout of Wheel Condition Monitoring System

Inrail installed wheelset diagnostic system

Wheel Condition Monitoring System •

Identi - fication

roundness and

flat spot

basic module

diameter cracks profile and

back to back

database

Remote access

Data exchange

Inrail I nstalled wheelset diagnostic system

Wheel Condition Monitoring System •

Identi - fication

roundness and

flat spot

basic module

diameter cracks profile and

back to back

database

Remote access

Data exchange

In Rail Installed Wheel Set Diagnostic System



19.0 Mobile Lifting Platform

(Aerial work lift platform)

Description : Battery powered aerial work lift platform with hydraulically

operated scissor lifts.

Source of supply : 1. JLG Industries Inc

1- JLG Drive,McConnellsburg,PA, USA

Contact person (India): Mr.Sunil Jain Reg.Mgr

Mobile no. 09810119569.

2. NeueroTechnologies GmbH, Germany

Cost : Rs.15 Lakhs



20.0 Coach lifting system

Description : Coach lifting system with under floor lifting plant and car

body stand.

Source of supply : 1. Neuero Technologies GmbH

Germany

Indian agent : M/s LAN Railtech. Pvt. Ltd.

K-1/81, C.R. Park, Ist floor

New Delhi-110019 Tel. 011-26271369, 26276449

Contact person : Mr.O.N.Jalota Jt.Managing Director

Mobile no. 09810158226

2. M/s Pfaff

D-86316, Friedberg/Derching,Germany


Lifting Jacks: 1. Jamalpur Workshop, Jamalpur

20.1 Photograph of Coach Lifting System



21.0 Wheel changing system

Description: Elevated track with split rail bridges and wheel set changer

Source of supply : 1. Neuero Technology

Germany

Indian agent : M/s LAN Railtech.Pvt.Ltd.

K-1/81, C.R.Park, Ist floor

New Delhi-110019 Tel. 011-26271369,26276449

Contact person : Mr. O. N. Jalota, Jt. Managing Director

Mobile no. 09810158226

2. Windhoff, Germany


21.1 Photograph of Wheel changing system



22.0 Automatic in-motion train washing system (ACWP)

Description : Automatic in-motion coach/train washing plant for exterior,

roof and under carriage cleaning with high pressure cleaning jet and with

vertical and horizontal rotating brushing unit .

Source of supply : 1. M/s Wesurail - US

2. M/s Bingham - UK

Cost : Rs.400/- lakhs

22.1 Photograph of Automatic in motion train washing system

Cleaning of coaches is the problem of the entire Indian Railways. Washing

and cleaning of coaches is one of the though and critical jobs to be carried

during train examination. The train movement on the such dusty/sultry

climate of the region, to ensure desired level of cleanliness of coaches of

Railways passenger trains is a real challenge. The rakes of these trains are

examined and maintained at C&W Depot During examination of these

rakes, internal and external cleaning and washing of coaches is being

carried out. It is observed and studied that oily & sticky smoke emitted by

Diesel Locos especially in tunnels result in sticky soot and stains being

formed on the coaches thus resulting in a real problem of cleanliness of the

coaches and this has attracted public criticism also. As the staff is limited,



the desired level of cleanliness cannot be done satisfactorily by

conventional method within limited time period.

22.2 AUTOMATIC COACH WASHING PLANT

To overcome the above problem of coach cleanliness, a method of external

cleaning of coaches by high-pressure water jet pump was adopted earlier.

Seeing at number of staff involvement in carrying out coach cleaning, coach

washing plant is developed by CAMTECH. In this plant, external cleaning

of coaches of a rake was done at NGP, Madgaon & Kurla by horizontal

rotating nylon brushes while passing through.

Eight powered nylon brushes were provided in this plant for the purpose of

rubbing of soap solution and cleaning of dirt on external surface of coach .

1.Stages of

a) Pre-wash,

b) Spraying of pressurized soap solution mixed with compressed air.

c) After wash with high-pressure water jet were developed and

incorporated in this washing plant.

In addition to horizontal nylon brushes, two Coir brush fixtures were

developed and fitted in this plant. These coir brushes were static (non-

rotating type) and fixed in one position for the purpose of even application

and rubbing of soap solution on surface of coach, thereby sticky particles of

soot and dirt get loosened and removed. But this coir brush could not touch

and clean the area near window-sills, upper and lower portions of coach

since upper portion of coir brush was obstructed by coach indication lamp,

indication board, destination board and lower curved portion (turn under) of

coach due to less stiffness of coir brush. Hence these portions were used

to be cleaned manually by available staff.

This plant is developed with keeping in view the following points in mind.

a) Less and economical maintenance of the modified washing plant.

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

c) 95% exterior cleaning of a entire rake of 24 coaches is to be achieved

within 35-40 minutes.

d) Reduction in water and soap solution consumption compared to the

conventional Manual coach cleaning.

e) Reduction in power consumption by using automation.

f) Cleaning and disinfection of underneath portion of toilet by High

pressure jets.

g) Bogie side cleaning by high pressure jets.

h) Roof cleaning of Coach by horizontal nylon brush.



23.0 LAYOUT AND CONSTRUCTION OF AUTOMATIC COACH

WASHING PLANT

The modified coach washing plant is situated at the entry point of rake

examination pit at coaching depot. There are four fabricated structures in

this washing plant.

1) First structure is having plan

area of 17sq.mtr. (5mX 3.4m)

and provided for PREWASH

stage. This structure is erected

at a distance of 30 meter from

second structure, to get

complete soaking of coach

with water.

2) Second structure is having

plan area of 8.16 sq.mtr.(2.4m

X 3.4m), is made from 300 x

150 mm ISBM & 300 x 90

mm ‘C’ channel This

structure is provided for the

stages of SPRAYING OF

SOAP SOLUTION and

Rubbing Of Soap Solution by

vertical nylon brushes.

3) Third structure of underneath

pipelines along with air and

water reservoirs having plan

area of (4.5mX3.4m)

15.3sq.mtr. and it is provided

at distance of 16mtr. from

second structure. This

structure is provided for stages of UNDERNEATH TOILET PORTION and BOGIE CLEANING.



4) Fourth structure is having plan area of

48 sq.m.(14m X 3.4m) and provided

for the stages of a) Moistening of soap

solution b) Roof cleaning by a

horizontal nylon brush c)Side cleaning

by four vertical cotton brushes. d)

After wash with high pressure jets.

e)Mopping by two vertical cotton

brushes. and Fourth structure is

erected at distance of 23 mtr. from

second structure, to get sufficient time

for reaction and complete soaking

with soap solution. near washing

plant.

This structure is located at start of pit line

is aligned and extended to old existing

structure of coach washing plant. It is

also made from same material used for

second structure. Central apron already

exists between the structure & track. It is

provided with proper drainage and

concrete apron in between structure and

track and nearby area at all above

locations so that waste water and soap

solution will drain out immediately to

adjacent main drainage and avoid

adverse effect on sleepers and track. Due

to proper apron and drainage,

accumulated dirt and waste are easily

cleaned and maintained with hygienic

condition.

OLD STRUCTURE OF PLANT

RENOVATED STRUCTURE

OF COACH WASHING

PLANT



Water is supplied from overhead tank of 40000 ltrs. capacity to underground tank

of 10000 liters capacity (shown in figure). Water from under ground tank is

supplied to coach washing plant for Pre wash and After wash stages, by 3 HP

pump along with stand by, are located inside pump house. Soap solution is made

in overhead plastic tank of 1000 ltrs. and this soap solution is supplied to coach

washing plant for Spraying of solution stage, by one HP pump. Water pipe

connections for Pre wash , After wash , Toilet and Bogie cleaning stages are made

from 1" and 2" pipes and soap solution pipe connection is from 1" pipe. Electrical

switchgears and control panel are provided for 3 Pumps (1 for soap solution and 2

for water),motors (each 3 hp)of 1 horizontal nylon roof cleaning brush and 6

vertical cotton brushes and 2 vertical nylon brushes for soap solution rubbing, in

the pump house which is located near to washing plant. Compressed air supply,

which is already available at pit line, is tapped for soap solution spray.

Both structures and vertical brush unit have been painted with two coats of epoxy

primer and paint. Since this Iron structure and sub assemblies are more prone to

corrosion due to existing salty weather and acidic/alkaline soap solution used in

washing plant, epoxy painting is one of the better options to reduce corrosion and

the cost.



24.0 PROCESS OF COACH CLEANING AND WASHING IN DIFFERENT

STAGES

24.1. PRE-WASH: A rake is moving at speed of 5 KMPH during cleaning

and washing of coaches through this plant. In this stage a diffuser type

sensor is provided for sensing coaches of a rake. As soon as this sensor

senses first coach of a rake, water starts spraying on external surface of

coach through number of holes provided on water pipelines erected around

in a row.

24.2. SPRAYING OF SOAP SOLUTION: In this stage, diluted soap

solution is sprayed on coach surfaces including two sides and roof through

seven sprinklers. Provision is made for mixing of compressed air with

pressurized soap solution inside the sprinklers to get more bubbles formed

when it strikes with coach surface.

Two sides and roof of

coaches are completely

wetted by low velocity

sprinklers at this stage,

some loose dust & dirt is

washed away from coach

surface and

simultaneously, coach

surface is made uniformly

wet, which help in even

application of soap

solution on coach body.

Due to release of surface tension in

bubbles, dirt particles are loosened

and washed away easily. Flow and

quantity of soap solution can be

controlled and adjusted by operating

spindle nut on sprinkler and both

valves provided on soap solution

line and pneumatic line.



24.4. SOAKING OF SOAP SOLUTION: In this stage, soap solution is

allowed to soak completely for approx.1 minute in normal washing process.

This stage is automatically achieved while rake is moving at 5 Km/h.

through coach washing plant, since stage 3 and stage 5 is kept apart at 30

meter distance. During this stage, soap solution, is chemically reacted with

dirt.

This pressurized spray clean underneath portion of toilet and near by area

which is normally spoiled with wet soil. This process is also helping in

prevention of breeding of cockroaches which generally take place in this

area. Further, it also helps in maintaining hygienic conditions for working

staff, who specially work or attend safety fittings in this portion of a coach.

In this stage, sides of bogie are also cleaned by high pressure water jets

simultaneously.

24.3.RUBBING OF SOAP SOLUTION: This stage is especially incorporated to get

more effective cleaning. In this stage, soap

solution is rubbed and made even

application on both sides of coach by two

vertical nylon brushes one at each side of

coach .This stage comes into action as

soon as sensor at second stage is activated.

24.5.CLEANING OF UNDERNEATH

PORTION OF TOILET: In this stage,

two sensors are provided for

ascertaining the location of underneath

toilet portion between two adjacent

coaches by sensing of last wheel of

first coach and first wheel of second

coach. As soon as these sensors are

activated in above situation,

pressurized water mixed with

disinfectant and phenol, sprayed from

bottom through four nozzles which are

provided between two rails.



24.6. MOISTENING OF SOAP SOLUTION: In this stage, moistening of

partially dried soap solution is carried out by sprinkling of very low-

pressure water through number of nozzles provided on a water pipe line.

Hence soap solution applied on roof and sides of coach become wet before

rubbing by horizontal and vertical brushes.

AAfftteerr tthhiiss ssttaaggee,, CCooaacchh iiss mmoovviinngg

ffuurrtthheerr tthhrroouugghh 44 sseettss ooff vveerrttiiccaall

ccoottttoonn bbrruusshh uunniittss ((22 NNooss oonn eeaacchh

ssiiddee)).. TThheessee bbrruusshheess aarree mmoovviinngg aatt

tthhee ssppeeeedd ooff 115500 rrppmm.. DDuuee ttoo

cceennttrriiffuuggaall ffoorrccee,, eenndd ooff eeaacchh tthhrreeaadd ooff

ccoottttoonn bbrruusshheess ssttaarrtt rruubbbbiinngg ssooaapp

ssoolluuttiioonn oonn ccooaacchh ssuurrffaaccee wwiitthh ssmmooootthh

iimmppaacctt eeffffeecctt tthheerreebbyy wwhhaatteevveerr

rreemmaaiinniinngg ssoooott aanndd ddiirrtt aavvaaiillaabbllee oonn

ssuurrffaacceess aarree ttaakkeenn aawwaayy ccoommpplleetteellyy..

CCoottttoonn tthhrreeaadd hhaass ggoooodd ccaappiillllaarryy

pprrooppeerrttyy tthhuuss iitt hhoolldd ssooaapp ssoolluuttiioonn

ccoonnttiinnuuoouussllyy ffoorr lloonnggeerr ttiimmee.. TThheessee

ccoottttoonn ttrreeaaddss hhaavvee ggoooodd fflleexxiibbiilliittyy aanndd

ggeett rreeqquuiirreedd lleennggtthh aauuttoommaattiiccaallllyy

aaccccoorrddiinngg ttoo sshhaappee ooff ssuurrffaaccee ooff ccooaacchh

ssoo tthhaatt oonnllyy ttiipp ooff tthhrreeaaddss ggeett ttoouucchheedd

wwiitthh ccooaacchh ssuurrffaaccee.. CClleeaanniinngg bbyy tthhiiss

mmeetthhoodd hhaass sshhoowwnn ssiiggnniiffiiccaanntt eeffffeecctt..

TThheessee ccoottttoonn tthhrreeaaddss aarree ssppeecciiaallllyy

ggiivveenn ssttiiffffnneessss bbyy ffaasstteenniinngg wwiitthh nnyylloonn

bbrriissttlleess ttoo pprreevveenntt mmiinngglliinngg ooff ccoottttoonn

tthhrreeaaddss..

TThheerreeffoorree,, ttiippss ooff bbrruusshheess aarree

rreeaacchhiinngg ,,ttoouucchhiinngg aanndd ddooiinngg cclleeaanniinngg

aatt iinnttrriiccaattee ppllaacceess oonn ccooaacchh bbooddyy lliikkee

wwiinnddooww,, wwiinnddooww ssiillll,, wwiinnddooww sshhuutttteerr,,

ddoooorrss ,, ssppaaccee nneeaarr ddoooorr iinncclluuddiinngg ddoooorr

hhaannddllee,, ssppaaccee nneeaarr ttoo ddeessttiinnaattiioonn

bbooaarrdd,, ttuurrnn uunnddeerr aanndd rrooooff ppoorrttiioonn..

EEaarrlliieerr,, tthheessee aarreeaa ccoouulldd nnoott bbee

ppoossssiibbllee ttoo cclleeaann bbyy oolldd ccooaacchh

wwaasshhiinngg ppllaanntt.. TThheessee bbrruusshheess aarree aallssoo

hheellppiinngg iinn rreemmoovviinngg ooff rreesseerrvvaattiioonn

cchhaarrtt ppaasstteedd oonn aa ccooaacchh..

24.7.COACH CLEANING BY HORIZONTAL AND VERTICAL BRUSHES:

WWhheenn ccooaacchh iiss mmoovviinngg tthhrroouugghh tthhiiss ssttaaggee,, ffiirrsstt rruubbbbiinngg ooff ssooaapp ssoolluuttiioonn ttaakkeess

ppllaaccee aatt rrooooff ppoorrttiioonn bbyy hhoorriizzoonnttaall nnyylloonn bbrruusshh mmoouunntteedd oonn ttoopp ooff tthhee IIVVtthh

ssttrruuccttuurree..



24.9.MOPPING OF WATER: After wash, coach body become

completely wet hence it require mopping. Two vertical brushes with

soft cotton threads are provided each on either side. These brushes

start mopping of water particles on sides of coaches as soon as coaches

pass through these brushes.

This stage is specially effective for

cleaning of AC glass windows where

small water drops are always sticking

and staining glass giving discomfort to

passengers when they are looking

outside through such windows. These

brushes are also used for buffing of

coaches to get shining by rotating it in

dried condition when rake is moved

from pit-line after examination. Since,

requirement of soap solution is less for

external cleaning of rake by this washing

plant. Cost incurred in normal external

cleaning of a rake of 21 coaches is Rs.

400 approximately. This cost includes

cost of material like soap solution and

cotton ropes (which are normally

replaced once in a month) and cost of

electrical power.

24.8. AFTER WASH: In this

stage, washing of roof and sides

of coaches are carried out after

rubbing of soap solution by

vertical and horizontal brushes.

High-pressure water is sprayed on

coach surface through eight high-

pressure sprinklers to wash coach

completely. In this stage, washing

of roof takes place just before

washing of sides by spraying of

water through high velocity

sprinklers provided at top of

structure. This arrangement is

made purposely to allow dirty

water after roof washing to flow

down on both sides of coaches

before washing of sides of

coaches.



25.0 INTERNAL COACH CLEANING MACHINE

This machine is departmentally designed and developed for cleaning of

coaches internally. It is operated on 220V AC as well as 110VDC supply

thereby any coach lying any where in the yard can be cleaned by this

machine as 110V DC supply available in a coach. Construction of this

machine is sturdy and light in weight about 6 Kg hence it is easy to handle.

Due to light weight and 1.2 meter length of machine, staff can do effective

cleaning work in standing position without fatigue. At present, this machine

is specially used for toilet cleaning and intensive cleaning of floor, berth,

side wall by using various type of brushes.

FLOOR CLEANING BERTH CLEANING

WINDOW GLASS CLEANING TOILET CLEANING



Suggestions given by Zonal Railways for Pre-Fab pit line during

seminar on 21.07.2014

Pit line: Dy CME/NWR, Sr DME/BSP & Dy CME/GKP stated that prefab pit line in line with

DMRC will be suitable but both side catwalks are required alongwith long span supports below

catwalk.

Catwalk: Catwalk is necessary for changing of destination boards, cleaning of exterior,

attention to doors, cleaning of roof and attention to ventilators. But these catwalks make clumsy

situation due to supporting pillars, hence it is suggested that pre-fab longer span catwalks may

be developed for better and safe maintenance.

Pre-Cast tiles: For free movement of staff from one pit line to other pit line at entry point, floor

of pre-cast tiles for atleast half of the coach length should be done for safe travelling.

Lighting arrangement: Light fittings of sufficient lux should be installed on Catwalk pillars for

under gear and trolley inspections. Single phase Welding sockets, and spare plug for hand lamps

should also be provided on this switch board.

Surface wheel lathe machine: Surface wheel lathe machine is required for coaching depots

having holding more than 250 coaches.

Maintenance bay shed: Lay out and estimation for covered shed should be done in line with

ROH depot ADI and TKD. The details may be collected from them.

Hydraulic Jacks: Hydraulics Howrah JET. And Ferro mysore are the sources for lifting

platforms.

Cleaning Machines: Sources for cleaning machines are , Karchar, Roots India, Johnson Divery

etc. Specifications may be collected from them

Documents

DRAFT REPORT ON PRE-FABRICATED PITLINE …rdso.indianrailways.gov.in/works/uploads/File/Draft...guidance of Mechanical engineers involved in maintenance of Coaching stock. It covers