STANDARDISATION OF INFRASTRUCTURAL FACILITIES FOR … Report on standarization of...Standardization of Infrastructural facilities for CC Rake Maintenance May- 2017 1 STANDARDISATION

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

CAMTECH/2017/M/CC-INF-STD/1.0

Standardization of Infrastructural facilities for CC Rake Maintenance May- 2017

1

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.



2

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.



3

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.



4

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.



5

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.



6

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



7

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



8

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



9

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



10

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



11

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.



12

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)



13

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



14

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 √ √



15


Sl

No.

Defects Examinati

on line


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 √ √



16


Sl

No.

Defects Examinati

on line


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 √ √



17


Sl

No.

Defects Examinati

on line


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

√ √



18


Sl

No.

Defects Examinati

on line


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.



19

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.



20

(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



21

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



22

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



23

Annexure-III-A



24

Annexure-III-B



25

Annexure-III-C



26

Annexure-III-D



27

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.



28

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.



29

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.



30

Annexure –V-B

Trial Conducted at PP yard Bhilai


(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.



31

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)



32

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.



33

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



34

(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


Future scenario

C. Detention per rake = 5 hrs.

D. Total rake hrs spent on examination ( AR_DP)= 50 hrs


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


= Net saving of rakes x net earning per rake – Addl.operating cost

= Rs.(1.795 x 16.05 ) – 1.43

= Rs. 27.37 Crores



35

Annexure-VI-B

Savings and advantages of the proposed facilities for

a model yard handling 10 rakes per day


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



36


= 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



37

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



38

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.



39

(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.



40

Annexure-VIII



41

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



42

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



43

(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.



44

Annexure-VIII-B



45

Annexure-VIII-C



46

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



47

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



48

Annexure-IX

MULTI - UTILITY VEHICLE



49

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



50

Sl.

No.


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



51

CHECK LIST FOR SICKLINE OF EXAMINATION YARD

Railway :……………Type of stock : …………Type of attention : … … …

Division : ………….. Avg. no. of coaches attended : …………

Sl.

No.


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



52

Sl.

No.


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



53

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.



54

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



55

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



56

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

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Documents

STANDARDISATION OF INFRASTRUCTURAL FACILITIES FOR … Report on standarization of...Standardization of Infrastructural facilities for CC Rake Maintenance May- 2017 1 STANDARDISATION