Quality Audit report

Of Coaching Depot Tikiapara, E Rly

Report no. 22/2012

APRIL 2012

(Audit is done by QA Mech Dte of RDSO )

Quality audit Report of TKPR Coaching Depot, Eastern Railway

1.0 Introduction Railway Board vide letter no. 2012/M(W)814/5 dated 20.3.12 has instructed RDSO / Zonal Railways to conduct quality audit of coaching depots and workshops. QA (Mechanical) Directorate has been assigned to carry out audit of 10 coaching depots. Kolkata Zone of QA(Mech)/RDSO has been assigned to carry out audit of 03 coaching depots (TKPR/HWH/ER, NCC/SDAH/ER and SRC/KGP/SER) by Executive Director/QA(Mechanical).

1.1 Audit team - S/Shri M A Alam, Director/I&L/Kolkata, S Bose, AIE/I&L/Kolkata and Dileep Kumar, JE/I&L/Kolkata & B K Sahoo, JE/I&L/Kolkata

1.2 Date of audit - 29.03.12 & 05.04.12 1.3 Escorting officers from depot - Sri S Vijay, Sr DME(C&W)/HWH & Sri Achinto Roychoudhary, CDO/TKPR, Sri P Mishra, SCW/TKPR and concerned SSE/C&W/TKPR.

1.4 Scope of audit - Primary maintenance of coaching rakes –under gear attention (pit attention) and rolling–in examination of terminating trains, coach cleaning, fitment of passenger amenities items, schedule attention of coaches ( POH, IOH, Schedule A and Schedule B), pest control management in AC and Non-AC coaches, detachment of coaches (primary, secondary and en- route) and its analysis, maintaining records –DDR (damage deficiency register), feedback/ complaint and action taken, linen management and availability of Stores & its management. After audit, Sr.DME/C&W/HWH and his team have been briefed about observation noted during audit.

2.0 Brief about visit  TKPR coaching depot, Howrah is one of the oldest coaching depot with holding of 740 coaches and is a major coaching depot of Eastern Railway.  Total 3 deep pit lines with catwalk as per CAMTECH design and other 12 deep pit lines without catwalk are available to carry out 18 primary maintenance, 1 secondary maintenance and 7 round trip maintenance of important Mail/Express trains such as Kolkata Rajdhani, Duranto Exp (HWH-NDLS), Ranchi Shatabdi, Bagh Express, Delhi Superfast and Doon Express etc.  Depot is also maintaining one Double Decker service (HWH–DHN) consisting of 7 coaches.  During two days of audit, items as per scope of audit have been checked. Relevant records have also been checked. Infrastructure availability in the coaching depot and planning of inputs has been studied. The escorting Page 1 of 39 Coaching depot – TKPR, E. Rly. April 2012

officers and supervisors have given all assistance to audit team and escorted the audit team during audit.

3.0 Strengths

3.1 Depot has provided LED destination board in 222 coaches of important Mail/Express trains against RSP. Coaches of Kolkata Rajdhani Express (12301/12302 &12305/12306), Duronto Express (12273/12274), HWH - DLI superfast (12323/12324) and 5 link trains of intercity express have been provided with LED destination board (including spare coaches).

3.2 Depot has installed one mechanized laundry as per RB’s guidelines. Total 3500 packets are washed daily from this mechanized laundry since last 15 months. Quality of washed linen is good. Depot has total requirement of 5000 packets per day. Balance quantity is arranged through washing contract in mechanized laundry. Close monitoring for linen quality is ensured. Complaints on account of linen have reduced to 4 cases in 2011–12 as compared to 50 cases in 2010–11.

3.3 OBHS through outsourcing as per RB’s guidelines has been provided in 14 important Mail/Express trains. In Duronto Exp (HWH – NDLS), HWH – NDLS Bi-weekly Express and other important M/E trains, OBHS through outsourcing have been provided. Depot is providing OBHS in LHB Rajdhani (HWH – NDLS) by deploying C&W staff. This has resulted in passenger satisfaction.

3.4 Depot is carrying out maintenance of CDTS, fitted in LHB coaches through in- house and all CDTS are working. Spares are procured through OEM. Depot has rigged up one CDTS test bench for testing of components before fitment in coaches.

3.5 Supervisor and staff are trained. Depot has good safety performance and there is no derailment / accident on C&W account.

3.6 Minimizing Jerk in LHB: ER has taken action to reduce jerks in LHB coaches. Draft gear pre-load has been reduced to 35 KN from 50 KN. Total 64 FTIL make and 14 Escort make CBC with draft gear have been fitted in LHB coaches. Complaints on account of Jerk reduced from 19 cases in 2010 – 11 to 02 cases in 2011 – 12.

3.7 Publication of Pocket Book on LHB & ICF type coach Maintenance & Trouble Shooting: To ensure safety maintenance - Pocket books for both LHB & ICF type coaches, contains Operation and Maintenance as well as Trouble shooting guideline have been published by the Division as a ready reference for Officers, Supervisors and staff.

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3.8 Improvement on ‘Last vehicle Indication’ ‘X’ mark on LHB type Rajdhani Power cars: In LHB Power car, last Vehicle indication i.e. yellow ‘X’ was rather small reducing its visibility specially in foggy season. The same has been improved by retro-reflective sheet for better visibility, especially during night time.

3.9 Provision of protection clamp on FTIL make brake calipers in LHB type Rajdhani coaches: To prevent dropping of brake pad from FTIL make brake calipers, depot has developed a ‘C’ type protection Clamp to prevent lateral movement of Snap lock. This will avoid en-route failure/detention of Rajdhani Express due to falling of brake pad.

‘C’ type protection Clamp

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3.10 Mesh-guard protection in air spring coaches for Duranto express: Depot has provided mesh-guard protection over air spring and air reservoir/piping in Hybrid Duranto coaches to avoid breakage of leveling valve & its’ assembly and prevent deflatening of air spring suspension system on run.

Protection covers for air spring Protection covers for air reservoir.

3.11 Divisional training school for training of Artisan and other category of staff: Depot has developed good facility to carry out training of various categories of staff in safety and housekeeping of coaching stock. A well established training school with full air brake model of coaching stock has been provided in depot for training of all categories of staff.

4.0 Weaknesses

4.1 Depot is not aware regarding list of safety items published by RB and following their own list of safety items. There is crisis of some safety items (K type brake block) and passenger amenities items. Non availability of cleaning

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and disinfecting chemical affects quality of cleaning. Stock of Oxalic acid for outside cleaning and pine oil for disinfection is critical. Quality of outside cleaning of trains (except Rajdhani) was found not satisfactory during audit on 28.03.12. For Rajdhani maintenance, better quality cleaning and disinfecting solution are procured through non-stock procurement.

4.2 Mechanized cleaning through contractual agency is carried out in 4 PM trains and 4 RTM trains. High pressure jet pipe lines are available for Rajdhani maintenance only.

4.3 Pest control is awarded to M/s Pest Control India. As reported by depot, Performance of existing pest control agency is not satisfactory. Close monitoring is required by depot for pest control through contractual agency. Depot has taken some additional initiative on its own for pest & rodent control management. Depot is also applying Boric acid under the berth. Due to close monitoring by depot, pest /rodent complaints during last six month (Oct’11 – Mar’12) is 6 cases as compared to 11 cases in the first six months (Apr’11 – Mar’11).

4.4 Regular feedback from coach attendant for linen quality and pest infestation are not available at depot.

4.5 Howrah Division (Engineering / Medical Department) has not taken any rodent control measure for platform area. Existing contract already has expired. Rodent control measure is available for depot area only (carried out by C&W department).

4.6 Manpower available for under gear examination and sick-line attention is 444 staff against requirement of 489 staff. Depot has processed for sanction of additional staff.

4.7 Passenger amenities in Non AC coaches (GSCN) such as magazine bags, bottle/tumbler holders and snack tables are missing. As reported by depot, shop is not providing these items in Non AC coaches. Snack table in NAC coaches are provided directly over L.P sheet and this worked out during service.

4.8 Reports of deficiencies/ defects in Rolling Stock (DRS) reports in the proforma given in Annexure 1.2 of CAMTECH manual are not prepared jointly. On arrival of the train at the destination station, joint report for deficiency in rolling stock has not been prepared.

4.9 D3 schedule of LHB coaches (six monthly schedule attentions) is not adequate as coach is not detached from rake for attention in sick-line. Attention is given at pit line in rake.

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4.10 With existing system, grease oozing out in LHB wheel sets can be checked from front seal only when front cover is opened. This is being checked during D2 /D3 schedule as front cover is opened for attention. For checking grease oozing out at rear grease seal, bottom control arm is to be taken out. Checking of grease oozing out in LHB wheel sets is not done for rear end seal at depot.

4.11 INFRASTRUCTURAL CONSTRAINTS OF TKPR: Depot has non-standard maintenance infrastructure. The following major bottlenecks have been reported by depot:

 Non standard Deep pits: Pits available are of non standard design without cat-walk.  Inadequate spacing between two pits: The space between two pits is narrow on account of track centre being less.  Curved Maintenance Line: All lines in yard are curved.  Inadequate drainage system – Existing drainage system is not adequate for complete drainage, especially during rainy season. The outlet through Howrah Municipality is almost blocked. Overall drainage system including lay out is required to be upgraded.  Remodelling work is in progress : To overcome the above constraints, the following remodelling of TKPR depot has been planned and works sanctioned:

 In PH-I: 03 deep pits of CAMTECH design with Catwalk have been constructed.  In PH-II: Sanctioned in PWP (10-11) at the cost of 45.04 crores. Total 04 deep pits with catwalk and one stabling lines with washing apron will be constructed.

4.12 Shortcomings have been noted in area which is not directly attributed to depot but need attention at respective level for better performance of coaching depot and reliability of rolling stock:

 Total 41 ICF wheel sets attended in sick-line due to grease oozing out during 2011-12. This need attention by concerned POH shop.

 There are 84 cases of primary detachments of ICF coaches due to water tank leaky in 2011–12 as compared to 69 cases in 2010–11. Depot has no facility for water tank testing. Only hydrant line is available.

 There are 22 cases of primary detachments due to DV defect (ICF coaches) in 2011–12 as compared to 13 cases in 2011–11. Total 08 cases of brake binding have been reported en-route during 2011–12. This need attention by concerned POH shop.

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 As reported by depot, adequate time at en-route watering station for coach watering has not been provided. Kolkata Rajdhani (HWH– NDLS) has only 10 mts stoppage time at MGS for coach watering.

 For facilitating inspection of sole bars, even spaced elongated holes of (215x127 mm) have not been provided in the turn under of all coaches. One coach in sick line has been checked and observed that coach ER 10421 (built ICF: 8/10 & POH/LLH -20.01.12) is not provided with elongated holes of 215x127 mm size.

 Contract for disc brake (including air brake) attention in LHB coaches for KB makes and FTIL brake systems have expired. Depot is carrying out maintenance attention of phonic wheel / speed sensor / brake caliper through in-house. As reported by depot, shop is not attending disc brake system during POH / IOH attention as contract with KB and FTIL expired and new contract is yet to be awarded by shop.

 Wheel sets are cannibalised during maintenance and wheel sets sent to shop when due for CTRB attention (at 3 years interval). It is observed wheel sets with life of more than 2 years are in service at depot without UST of axle. As per guidelines circulated by DG/M&C/RDSO vide letter no. M&C/NDT/1/8, ICF axle need to be given UST at one year interval. No such guidelines have been circulated for LHB wheel sets. Presently LHB axle is attended for UST when wheel sets touch the workshop. Due to absence of guidelines for LHB wheel sets, depot is not attending wheel sets for UST of axle.

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Quality Assurance Directorate (Mechanical) RDSO Lucknow Check sheet for Quality audit of coaching depot Primary maintenance attention and sick line attention (Based on CAMTECH Maintenance Manual for BG coaches and Railway Board / RDSO’s guidelines)

Location: TKPR Coaching Depot, Howrah Date of audit: 28.03.2012 & 05.04.12

S.N Item Clause Observation 1 Periodicity of periodic overhauls 103 of Chg.Manual Table Periodicity of POH as per Railway (POH) in designated workshops is 1.1 and correction slip 5 Board’s guidelines is followed. being followed. issued in 2008 ICF & LHB coaches are given POH RB letter no. 2007/M ( attention at LLH shop. C)/141/1 dtd 26.09.08 Status of POH attention during 2011 - 12 is as under: AC 158 NAC 826 Total 984

Overdue POH as on 01.04.12 is nil. 2 Maintenance schedules to be 112(a) of Chg. Manual an TKP Depot/HWH has a bare holding followed in coaching depots Correction slip 5 for of 613 coaches and total holding of To maintain coaching stock in coaching maintenance 740 coaches (including maintenance good condition, the following manual issued in 2008 spare and traffic spare). ICF maintenance schedules are coaches – 604, LHB – 75, Duronto prescribed to be carried out in RB letter no. 2007/M ( carriage depots on divisions C)/141/1 dtd 26.09.08 (Hybrid) - 28, Double Decker – 17 & where rake has been based for Satabdi (Conv) – 16. primary maintenance. Schedule A & B attentions in rake are being carried out as per recommended frequency for ICF coaches. LHB coaches are also 3 Schedule A - Monthly (1 attended as per recommended month ± 3 days) in rake frequency. (D2 schedule at one 4 Schedule B -Quarterly (3 month ± month interval and D3 at six month 7 days) in rake interval). 5 IOH attention - detach coaches During last 6 months, Periodicity of IOH attention: Page 8 of 39 Coaching depot – TKPR, E. Rly. April 2012

S.N Item Clause Observation Coach Total A schedule carried out : 2072 Periodicity Category Total B schedule carried out: 849 at interval of 12 Overdue A and B schedule: NIL New coach months in Depot Existing sick line at TKPR depot at interval of 9 Rajdhani has 5T crane facilities. 25T carne is months in Satabdi workshop under installation. IOH attention is (Conv) given at LLH shop as well as depot. Mail / at interval of 9 Lifting at depot is being done by JMP Express months in depot Jacks. Total 16 nos. jacks are at interval of 9 available at sick-line. Shop is Passenger months in depot supplying overhauled bogies. BRN at interval of 12 Other OCVs wagons have been converted with months in depot provision of screw coupling. Bogies are supplied to depot in BRN wagon Tolerance for IOH may be kept as and arrived/dispatched with POH + 30/-0 days. load. Newly built coaches (ICF Maintenance activities to be carried out during schedules design) are attended at SYAE should be as per Appendix-F & G. Depot/HWH as per Board’s For IOH attention of newly built guidelines. coaches, guidelines as circulated During 2011, status of IOH attention vide RB’s letter no. 2007/M ( for ICF design coach is as under: C)/141/1 dtd 06.08.09 IOH attention at LLH shop 347 IOH attention at Depot 104 IOH attention of newly built - coaches Total IOH attention of 451 coaches at depot Overdue IOH coaches: NIL Sick line has capacity of 16 coaches under cover shed /overhead crane facility. Pit facility is available for …… coaches. 6 Primary maintenance schedules 112(b) of Chg.Manual This is being followed. The depot is are required to be carried out by carrying out the following attention at the base depots to which coaches depot: are allotted. In emergency, when Mail Express trains due to any reason coaches cannot reach their base depots PM with RTM at other end 13 and primary maintenance PM with SM at other end 5 schedules become due, A & B RT attention (other base) 5 schedules should be undertaken RT attention (own base) 2 by the carriage depots where the SM attention of other base 1 coaches are available. ‘C’ Total attention 26 schedule should be done at base depot. Total 47 coaches are missing over Foreign Railways. These coaches returned to base depot when due for POH. 7 Examination of originating trains: 107 a of Chg. Manual

7.1 All trains must be examined by 107 a (i) of Chg. This is being followed. All trains are the mechanical train examining Manual examined by C&W staff before staff before despatch to ensure all despatch. coaches are in fit condition without rejectable defects. Page 9 of 39 Coaching depot – TKPR, E. Rly. April 2012

S.N Item Clause Observation 8 Terminating Examination of 107 b of Chg. Manual Rolling–in examination is being Passenger Trains – Rolling in carried out at HWH. Deployment of examination. staff have been checked during audit and found only 2 men deployed for rolling-in examination. 8.1 Site shall provide unobstructed 107 (b)(i)(a) of Site has un-obstructed view of under view of under gear from both Chg.Manual gear from both side. sides.

8.2 Should have adequate space for 107 (b)(i)(d) of Lighting arrangement for rolling–in fixing the lighting arrangement Chg.Manual examination is available. Light and for staff arrangements have been provided at both side of PF-1 to PF -14. These arrangements cover all in-coming Mail/Express trains. 8.3 As the train passes the nominated 107(b)(iv) of Chg.Manual Records of rolling – in examination point, C&W staff should watch out have been checked. Temperatures of vigilantly for loose/hanging/broken all axle boxes of under gear parts of the coaches, Rjadhani/Duronto/Satabdi have been any unusual sound coming from recorded in register. Temperature of the coaches or any other abnormality in the coaches. axle boxes of ICF coaches if above 500C has been recorded. Depot has been intimated by PH TXR for any defects noted during rolling-in examination. However, during audit check on 14.04.12, rolling-in staffs were found standing at site but not carrying out rolling-in examination of Shipra Express during arrival at PF. 8.4 Temperature of the axle boxes 107(b)(vi) of Chg.Manual Axle box temperature is measured should be measured preferably with non contact type temperature with the help of the electronic measuring device. 06 nos non- temperature measuring device. contact infrared temperature measuring devices are available at PF. 9 Revised maintenance pattern Railway Board’s letter for coaching trains circulated No.95/M(C)/141/1 vide Railway Board’s letter dt.31.01.07 No.95/M(C)/141/1 dt.31.01.07 9.1 While permitting introduction of Railway Board’s letter This is being ensured. round trip primary pattern of No.95/M(C)/141/1 maintenance on coaching trains, dt.31.01.07 approved mandatory condition at primary end and other end as detailed in Railway Board’s letter No.95/M(C)/141/1 dt.31.01.07 is followed. 9.1.1 Primary End i) The brake gearing should be -do- ICF Coaches have been provided properly adjusted including the with BMBC. Piston stroke is adjusted slack adjuster ‘A’ dimension & the to 32 mm during primary brake cylinder stroke to ensure maintenance. 100% brake power ii) Brake blocks should be changed -do- This is being ensured. in bogie sets only iii) All missing passenger amenity -do- All AC coaches are provided with Page 10 of 39 Coaching depot – TKPR, E. Rly. April 2012

S.N Item Clause Observation fittings must be replaced and the passenger amenities items. However, rake must be turned out as ‘Zero- passenger amenities in Non AC Missing-Fitting’ rake. coaches such as magazine bags, bottle/tumbler holders and snack tables are missing. As reported by depot all passenger amenities items are not provided in Non AC coaches during POH. Snack table in NAC coaches are provided directly over L.P sheet and this worked out during service. iv) Intensive cleaning of coach toilets -do- This is being ensured. and lavatory. v) Clear maintenance time of 6 -do- Clear maintenance time of 6 hrs on hours on the pit as per train the pit is available as per train schedule. schedule.

vi) Provision of proper washing cum -do- TKPR depot has the following pits maintenance pit line facility with and stabling line for rake adequate testing equipment and maintenance: high pressure jet cleaning plant at 24 coach pit with 03 primary end. catwalk and washing apron 24 coach pit facility 04 without catwalk Less than 24 coach pit 08 facility Stabling line with 24 NIL coach facility Stabling line with less 3 than 24 coach facility

TKPR pits are non standard without catwalk and washing apron. Only 3 pits have been constructed as per CAMTECH design. Works have sanctioned for construction of 4 deep pits of CAMTECH design and one WA cum stabling line. 10 nos. RTR is available for air brake testing. High pressure line is available for Rajdhani maintenance pit line only (pit line 36 & 37). Facility for High pressure jet is not available for coach washing and toilet cleaning in other pits. vii) Adequate gang strength with -do- The staffs available for cleaning proper supervision activity are 290 against requirement of 304. Shortfall has been compensated through outsourcing of cleaning activity. Total 65 staff deployed for cleaning activity through outsourcing. Page 11 of 39 Coaching depot – TKPR, E. Rly. April 2012

S.N Item Clause Observation Manpower available for under gear examination is 335 staff against requirement of 354 staff. Manpower available for sick line attention is 109 staff against requirement of 135 staff. 9.1.2 The Other End

i) Whenever the lie-over is more -do- This is being ensured at other end. than 2 hours at the platform or the rake is stabled in the yard, the rake should be locked and positive security should be provided

ii) The minimum infrastructure to be -do- This is being ensured at other end. provided at the platforms from where trains are returned without secondary maintenance should be is available iii) A joint safety certificate covering -do- Joint certificates have not been each clause of mandatory issued for newly introduced train by conditions will be issued by Sr.DME/C&W and Sr.DOM. Total 06 mechanical and operating new trains have been introduced, branches at divisional level prior however, joint certificate covering to changing over any train to revised coaching maintenance each clause of mandatory conditions pattern. have not been issued. 10 Rake maintenance link has 108 of Chg. Manual and Rake maintenance link has provision provision of maintenance time (pit Policy circular no. 4 of 6 hrs maintenance time for pit attention) of 6 hrs at primary end attention at primary end. to enable intensive attention. 11 Internal cleaning, Passenger 108 of Chg.Manual Table Attention is given for rake cleaning, amenity attention and watering is 1.8 amenities attention and watering at done at platform line or pit line. nominated stabling line provided stipulated facilities are available at such line is followed 12 Washing and cleaning of 109 of Chg.Manual coaches

12.1 Use recommended solutions for 109 of Chg.Manual Depot is using solution for cleaning cleaning as per RDSO as approved by CME. Cleaning specification No. solution is provided by contractual M&C/PCN/101/2001 or use agency for the coaches undertaken cleaning agents approved by for cleaning activity (43 coaches of CME of the Railway PM and 65 coaches of RTM) as per contracts provision. Against MC of 3200, average consumption is only 1452. There is crisis of cleaning and disinfecting items such as Oxalic acid, Pine oil etc. this is affecting cleaning quality of rake maintenance. 12.2 It should be ensured that the 109 (b)(i) of Chg.Manual Wooden wedges are applied to avoid rake/coach is protected with rolling down of rake and red proper board/signal for safety of protection board is applied. the staff working on washing/cleaning job to prevent movement/disturbance in the Page 12 of 39 Coaching depot – TKPR, E. Rly. April 2012

S.N Item Clause Observation activity. Scotch blocks with locking arrangement should protect lines and keys should be kept with Engineer (C&W) till the time rake is under maintenance 12.3 External cleaning /washing: 109 (b) of Chg.Manual Coaches of 13009 up and 12301 up Check that guidelines as detailed have been checked during audit on in CAMTECH manual are being 29.03.12. External cleaning is found followed. satisfactory in 12301 Up. However, outside cleaning is not satisfactory. 12.4 Cleaning of Toilet: 109 (c) of Chg.Manual Coaches of 13009 up and 12301 up Check that guidelines as detailed have been checked during audit on in CAMTECH manual are being 29.03.12. Cleaning of toilet is found followed. satisfactory. 12.5 Internal cleaning of upper class 109 (d) of Chg.Manual Coaches of 13009 up and 12301 up AC and sleeper coaches: have been checked during audit on Check that guidelines as detailed 29.03.12. Internal cleaning of AC in CAMTECH manual are being coaches in 12301 is found followed. satisfactory. However, internal cleaning of 13009 needs more improvement. 12.6 Internal cleaning of GS, SLR: 109(e) of Chg.Manual Coaches of 13009 up have been Check that guidelines as detailed checked during audit on 29.03.12. in CAMTECH manual are being Internal cleaning of GS and SLR is followed. satisfactory. 12.7 Cleaning of buffers and screw 109(f) of Chg.Manual couplings (i) Buffer plungers should be 109(f)(i) of Chg.Manual This is being ensured. scrubbed with a scraper to remove dirt and muck. Thereafter, they should be wiped clean with cleaning oil and rubbed with coir rope. (ii) Screw coupling threads should be 109(f)(ii) of Chg.Manual This is being ensured. cleaned with wire brush to remove all dirt and dust. Thereafter, it should be cleaned and given a light coat of oil. Oiling should be done on slack adjuster also 13 Conditions required for 110 of Chg.Manual maintenance of 24 coach trains (Railway Board’s letter No.98/M(C)/137/19 Pt.I dt.28.7.99 & 5.5.2000 13.1 Infrastructural requirements 110(a) of Chg.Manual

(i) 24 coach length fully equipped pit 110(a)(i) of Chg.Manual TKPR depot has 3 (three) deep pits line. with 24 coach facility. Only one train (12323 Up) is 24 coach length trains. (ii) High pressure jet cleaning 110(a)(ii) of Chg.Manual Cleaning is being done with normal pipeline with plant for cleaning at hydrant line and high pressure jet line primary pit line. Mechanized is available for Rajdhani attention external cleaning is preferable only. (iii) Water hydrants for 24 coach 110(a)(iii) of Chg.Manual For en-route watering, adequate time length at en route watering at en-route watering station has not stations with 20 minutes stoppage been provided for Kolkata Rajdhani at nominated stations (12301/12302 & 12305/12306) has Page 13 of 39 Coaching depot – TKPR, E. Rly. April 2012

S.N Item Clause Observation stoppage time of 10 mts at MGS for coach watering. (iv) Availability of the prescribed air 110(a)(iv) of Chg.Manual Total 10 nos. RTR are available for brake maintenance and testing air brake testing. Air pressure is 10 – equipment. 7.5 Kg/cm2.

Compressor of 500 CFM (3 nos) and

360 CFM (1 no.) are available at depot.

13.2 Coach Design related 110(b) of Chg.Manual requirements (i) Air brake with twin pipe graduated 110(b)(i) of Chg.Manual This is being ensured release system

(ii) Only enhanced capacity draw 110(b)(ii) of Chg.Manual All ICF coaches have been provided gear and screw coupling to RDSO with enhanced capacity draw gear sketch No. 79061 and 79067 are and screw coupling (75 T capacities). to be provided on the rake LHB /Duronto coaches are provided with H type CBC. 13.3 Maintenance practices and 110(c) of Chg.Manual system related requirements i) The integrity of the rakes to be 110(c)(i) of Chg.Manual Integrity of rake is maintained. maintained.

ii) Primary maintenance of the rake 110(c)(ii) of Chg.Manual This is being ensured should be done in one hook without splitting iii) Minimum maintenance time of 6 110(c)(iii) of Chg.Manual This is being ensured hours on the pit during primary maintenance iv) It is mandatory to provide 110(c)(iv) of Chg.Manual This is being ensured. RPC 4 has secondary maintenance to all been revised and PM with round trip trains augmented to 24 coaches is permitted up to 3500 Km for 24 (RPC 4 revised and permit Round coaches’ trains also. trip attention with approval of CME) v) Trains leakage rate to be 110(c)(v) of Chg.Manual This is being ensured. Air brake maintained within prescribed testing is being done with RTR. limits by using rake test rig. vi) Provision of proportionate brake 110(c)(vi) of Chg.Manual Air flow measuring valve has been system on the locomotive in good provided in locomotives working order vii) Provision of audio visual alarm 110(c)(vii) of Chg.Manual system on the locomotive 14 Fire extinguishers should be 111(f)(i) of Chg.Manual Quarterly and yearly attention as checked every three months and stipulated is provided through completely refilled after one year. outsourcing.

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S.N Item Clause Observation 14.1 Provision of DCP type fire RB’s letter no. 95/Sec DCP type FE’s are provided as extinguisher in a rake should be (spl)/75/1 dtd 30.05.97 under: in accordance with guidelines circulated vide letter no. 95/Sec AC / SLR – 2 nos each (spl)/75/1 dtd 30.05.97 Pantry car – 04 nos. Coach type Nos of FE’s Generator car – 02 nos. Each Break Van 2 nos Each AC coach 2 nos Each Pantry car 4 nos Each Generator 2 nos van

15 Similarly, other brake van 111(g)(i) of Chg.Manual C&W department is providing FE’s equipment, which Mechanical and wooden wedges in trains. Other Train Examining staff is equipments are provided by TL, S&T responsible to supply, should be and traffic staff. provided according to the All items of brake van have been instructions of each Railway. Portable control telephones, kept in SLR and Almirah is sealed. portable train lighting equipments, portable fire extinguisher, wooden wedges/skids and stretcher are to be provided. 16 Watering and cleaning of rakes 111(h) of Chg.Manual ASN & MLDT are nominated CTS in Mechanical department of each ER. railway will nominate the watering Watering station is ASN, MLDT and and the cleaning stations on the RPH in ER railway. 17 Deficiency Rolling Stock (DRS) 111(i) (i) of for Coaching Stock (i) Railway should devise system for Chg.Manual This is not being followed. DRS detecting deficiencies. Reports of reports are not prepared jointly. deficiencies/ defects in Rolling Stock (DRS) reports in the proforma given in Annexure 1.2, should be prepared for each mail/express/passenger originating train in duplicate by the Engineer (C&W)/Electrical (TL) and should be signed jointly with the RPF representatives. (ii) On arrival of the train at the 111(5)(b) of Chg.Manual This is not being followed. destination station,, the Engineer (C&W) staff and electrical staff shall check the rakes jointly with a representative of RPF and comparison may be made with original report. 18 Coach Maintenance History 111(k)(i) of Card (i) Every coaching depot shall have Chg.Manual Coaching depot is maintaining coach computers for maintaining the maintenance history in computer (in coach maintenance history in a Access based software) which is software programme which accessible to coaching depot officer should be compatible with the and supervisors. However coaching programme of the coaching workshop. workshop is not linked with depot for assessing coach history. During POH, depot is furnishing coach Page 15 of 39 Coaching depot – TKPR, E. Rly. April 2012

S.N Item Clause Observation history details to shop in hard copy.

(ii) The complete history book of 111(k)(iii) of Chg.Manual This is not being followed. each coach, consisting of maintenance history cards, date card, trial card, etc. will, however, be maintained by the base workshops 19 Primary/Secondary maintenance 19.1 The rakes/ coaches of all trains 113(a) of Chg.Manual This is being followed. The depot is should be given a carrying out the following attention at Primary/Secondary Maintenance depot: examination as prescribed by the Mail Express trains Chief Mechanical Engineer of the Railway and as per Appendix F of PM with RTM at other end 13 Chg.Manual PM with SM at other end 5 RT attention (other base) 5 RT attention (own base) 2 SM attention of other base 1 Total attention 26

19.2 Coaches shall be washed and 113(b) of Chg.Manual This is being followed. cleaned thoroughly from outside and inside as prescribed in clause 109. 19.3 Brake system maintenance 113(c) of Chg.Manual This is being followed. Air brake system (Bogie mounted and underframe mounted): Attention as detailed in para 113 ( c) is being given during primary /secondary attention of a rake. 19.4 In addition to above the following 113 (d) of Chg.Manual This is being followed. However, items of work should be attended under gear cleaning is not during the maintenance schedule satisfactory to facilitate examination examination: of under-frame, bogie frame, axle * underframes box and springs etc. * bogie frames * axle boxes * springs. These items should be wiped with wet waste weaves or cotton waste as necessary so as to facilitate examination. All under gear components should then be examined and repaired as necessary to ensure that there is no `S' marked rejectable defect as mentioned in Chapter IV of IRCA Conference Rules. 19.5 The following items of under-gear 113 (e) of Chg.Manual This is being followed. components should, however, be specially examined and attended to:- i) Oil in hydraulic dash pots of 113 (e) (i) of Chg.Manual Oil level in dash pot is checked on Rajdhani and Shatabdi coaches monthly basis and oil is filled up on Page 16 of 39 Coaching depot – TKPR, E. Rly. April 2012

S.N Item Clause Observation should be checked once in 15 need basis. days to detect oil leakage from them through defective seals or through the vent screw. Add/ replenish with specified grade of oil if the oil level is below 40 mm in the tare condition for ensuring better riding comfort. ii) Wheel profiles should be visually 113(e)(ii) of Chg.Manual This is being followed. examined and gauged in case they appear to be near condemning limits.

iii) The brake gear should be 113(e)(iii) of Chg.Manual This is being followed. ICF coaches checked and so adjusted that the have been provided with BMBC and piston stroke is within the limits piston stroke is adjusted to 32 mm by specified for different types of depot during PM. coaches. (see table 1.10). 'A' and 'e' dimensions for slack adjuster should be as per table 1.11 (as applicable for under frame mounted brake system) 19.6 The following coach body 113 (f) of Chg.Manual components and fittings should be specially checked and attended to i) Doors should be properly secured 113(f)(i) of Chg.Manual This is being followed. with the hinges/pivots and should not be grazing with floor or door sill plates. ii) Door latches and safety catches 113(f)(ii) of Chg.Manual This is being followed. iii) Door lock handles 113(f)(iii) of Chg.Manual This is being followed. iv) Tower bolts 113(f)(iv) of Chg.Manual This is being followed. v) Window shutters should neither 113(f)(v) of Chg.Manual This is being followed. be tight nor loose vi) Window shutter safety catches 113(f)(vi) of Chg.Manual This is being followed. vii) Window frame 113(f)(vii) of Chg.Manual This is being followed. viii) Vestibule assemblies of all 113(f)(viii) of Chg.Manual This is being followed. vestibule coaches should be checked and repaired as necessary. ix) Water pipe connections, flushing 113(f)(x) of Chg.Manual This is being followed. valves, cocks and shower roses should not be leaking or choked. x) Drain grills and drain holes in the 113(f)(xi) of Chg.Manual This is being followed. bathroom floors and wash basin drainpipes should be cleaned and opened where found choked. xi) Any other deficiency as per 113(f)(xii) of Chg.Manual This is being followed. Annexure 1.2 should be made good.

xii) A proper record should be kept 113(h) of Chg.Manual Depot is maintaining record of PM in by Engineer (C&W) at DDR. Records for Upper body and washing/pit lines of schedules under gear are maintained in one carried out by them, especially register. All relevant records are of items required to be maintained for rake wise during PM Page 17 of 39 Coaching depot – TKPR, E. Rly. April 2012

S.N Item Clause Observation attended at specific periodicity. of rake. Record to be maintained in standard DDR (Damage deficiency register) 20 Schedule ‘A’ Examination 114 of Chg.Manual i. Schedule `A' is required to be 114 (a) of Chg.Manual This is being followed. given every month + 3 days at the nominated primary maintenance depot within the normal primary maintenance time on a washing/pit line in a rake.

ii. Brake system maintenance 114(b) of Chg.Manual This is being followed. Air brake system (bogie mounted) A schedule maintenance as per air brake chapter iii. The specified items of work 114(c) of Chg.Manual This is being followed. should be attended during Record of schedule ‘A’ examination Schedule ‘A’ examination, i.e. is maintained in printed schedule monthly examination. form.

21 Schedule ‘B’ Examination 115 of Chg.Manual i. Schedule `B' is required to be 115(a) of Chg.Manual This is being followed. given every three months + 7 days at the nominated primary maintenance depot within the normal time allowed for primary maintenance on a washing line in rake. ii. The specified items of work 115(b) of This is being followed. should be attended. Record of schedule ‘B’ examination is maintained in printed schedule form. iii. Brake system maintenance Chg.Manual This is being followed. Air brake system (Bogie mounted) (i) Same as 'A' schedule iv. Other assembly maintenance This is being followed. Besides brake system other items 115(b)(i) of Chg.Manual should be attended as given below: a. All items of Schedule`A' 115(b)(ii) of Chg.Manual This is being followed. b. Painting of lavatories from inside. 115(b)(iii) of Chg.Manual This is not being followed. Attention is given on need basis. c. Thorough inspection and repairs 115(b)(iv) of Chg.Manual This is being followed. of brake gear components. d. Thorough checking of trough 115(b)(v) of Chg.Manual This is not being followed. floor, turn unders, etc., from underneath for corrosion. e. Touching up of painted portion, if 115(b)(vi) of Chg.Manual This is not being followed. Attention faded or soiled. is given on need basis. 22 IOH attention 116 of Chg. Manual and Correction slip 5 for coaching maintenance manual issued in 2008 22.1 Periodicity of IOH attention: 117(i) of Chg. Manual Existing sick line at TKPR depot Coach and correction slip 5 for Periodicity has 5T crane facilities. 25T carne is Category coaching maintenance under installation. IOH attention is New coach at interval of 12 manual issued in 2008 Page 18 of 39 Coaching depot – TKPR, E. Rly. April 2012

S.N Item Clause Observation months in given at LLH shop as well as depot. Depot Lifting at depot is being done by JMP at interval of 9 Rajdhani Jacks. Total 16 nos. jacks are months in Satabdi (Conv) available at sick-line. Shop is workshop supplying overhauled bogies. BRN at interval of 9 wagons have been converted with Mail / Express months in depot provision of screw coupling. Bogies at interval of 9 are supplied to depot in BRN wagon Passenger months in and arrived/dispatched with POH depot load. Newly built coaches (ICF at interval of 12 design) are attended at SYAE Other OCVs months in Depot/HWH as per Board’s depot guidelines. Tolerance for IOH may be kept as During 2011, status of IOH attention + 30/-0 days. for ICF design coach is as under: Maintenance activities to be carried out during schedules should be as per Appendix-F & G. IOH attention at LLH shop 347 For IOH attention of newly built IOH attention at Depot 104 coaches, guidelines as circulated IOH attention of newly built - vide RB’s letter no. 2007/M ( coaches C)/141/1 dtd 06.08.09 Total IOH attention of 451 coaches at depot Overdue IOH coaches: NIL

For newly built coaches, RB’s guidelines are followed. 22.2 Coaches are required to be 117(ii) of Chg.Manual For IOH attention, coaches are detached from the rake and taken and Correction slip 5 for detached from rake. to the sick line or sent to shop for coaching maintenance IOH attention (‘C’ schedule manual issued in 2008 maintenance) 22.3 Brake system: ‘C’ schedule 117(a)(i) of Chg.Manual This is being followed. IOH coaches maintenance (IOH) as per para after attention at shop for bogies are 426 of air brake chapter. attended at depot for IOH attention of upper body and air brake items.

22.4 Thoroughly clean Dirt collector 117(a)(vii) of Chg.Manual Attended at depot for off IOH filter in kerosene or replace on coaches as well as for coaches taken condition basis. for IOH attention at depot. At shop, only bogies are overhauled and attention to air brake system and upper body is given at depot. However, intensive cleaning of off IOH coaches are not being carried out. 22.5 Other assemblies maintenance 117(a)(i) of Chg.Manual Attended at depot during IOH All items of Schedule `B' attention of coaches at depot. 22.6 Thorough repairs of running gear 117(a)(ii) of Chg.Manual This is being followed. Bogies are including running out of bogies overhauled during IOH attention at where considered necessary. All shop. In addition, shop is supplying bogies which are working on rake bogies to depot for IOH attention. links earning more than 2.5 lakhs

kms. per annum must however be run out and thoroughly attended to as laid down in clause 111c under “Intermediate Overhaul”.

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S.N Item Clause Observation 22.7 Touching up damaged paint of 117(a)(iii) of Chg.Manual Attended at depot during IOH coaches on outside as well as attention of coaches at depot. inside. 22.8 Polishing of the polished 117(a)(iv) of Chg.Manual This is not being followed. surfaces. 22.9 Shock absorbers should be 117(a)(v) of Chg.Manual Attended at shop during overhauling replaced and sent to the base of bogie. workshops for repairs, testing and return. For this purpose, adequate spares must be maintained in the depot. 22.10 Thorough cleaning and removal 117(a)(vi) of Chg.Manual This is not being followed. of dust, rust, dirt, etc., accumulated at the pillars through the turn under holes, with coir brush and compressed air. 22.11 Thorough examination and 117(a)(vii) of Chg.Manual This is being followed. repairs of upholstery, cushions, curtains, etc. 22.12 Thorough checking and full 117(a)(viii) of Chg.Manual This is being followed. repairs of all window shutters, safety catches, safety latches, staples and hasps of compartment, lavatory, 22.13 Thorough checking and repairs of 117(a)(ix) of Chg.Manual This is being followed. UIC vestibules, their rubber flanges metal frames, doors, fall plate, locking gear, etc., for ease of operation and safety . 22.14 Thorough checking and repairs of 117(a)(x) of Chg.Manual This is not being followed. all cracks and worn out portions of flooring of the compartments.

22.15 Engineer (C&W) of Primary 117 (d) of Chg.Manual For facilitating inspection of sole bars Coaching Maintenance Depots even spaced elongated holes of should be fully familiar with the (215x127 mm) are not provided in vulnerable areas of ICF coaches the turn under of all coaches. One for corrosion, viz., sole bar at coach in sick line checked and found doorways, lavatories and adjoining areas, corridor sides - that coach ER 10421 (built ICF: more so in case of those SLRs 08/10 & POH/LLH- 20.01.12) is not which are used for Fish, Salt, etc. provided with elongated holes of For facilitating inspection of sole 215x127 mm size. bars even spaced elongated holes of (215x127 mm) are already provided in the turn under. 22.16 Special attention should be taken 117(e) of Chg.Manual for the following:- i) Pocket between sole bars and 117(e)(i) of Chg.Manual This is not being followed. turn under should be thoroughly cleaned through the inspection opening of the sole bars and inspected with the help of torch light or inspection lamps. II). Drain holes provided in the trough 117(e)(ii) of Chg.Manual This is being followed. floors should be kept clean and unclogged. If during the cleaning of these drain holes any accumulation of water is observed, the affected area

Page 20 of 39 Coaching depot – TKPR, E. Rly. April 2012

S.N Item Clause Observation should be very carefully inspected for possible corrosion. III) A register should be maintained 117(e)(iii) of Chg.Manual Records of Schedule A, B attention of the primary maintenance are maintained in standard format. coaches on the subject. For IOH attention at depot, record is Record of Schedule A, B and IOH maintained in standard format for attention are maintained in upper body and under gear attention. standard format and records are maintained. For IOH attention at shop, record for balance items of upper-body and air brake is maintained. 22.17 For maintenance of coaches of 118 (b) of Chg.Manual LHB coaches have been provided in Rajdhani/ Shatabdi Express Rajdhani Expres. Hybrid coaches Rakes, the instructions given in have been provided in Duronto RDSO Technical Pamphlet No. C- Express (HWH – NDLS). ICF 7807 should be followed. coaches have been provided in Satabdi Express. 22.18 The IOH of Rajdhani/Shatabdi 118(c) of Chg.Manual IOH attentions of Rajdhani are high speed coaches should be carried out in LLH shop. carried out in workshops 23 Linen management

i. Complete activity of linen Board’s letter C&W department/HWH is carrying management including washing, No.2009/M(C)/165/6 out complete activity of linen storage, supply & distribution of dt.17.12.2009. management. However, distribution linen kits in trains shall be done is being done by electrical by Mechanical (C&W) Dept as a department & Commercial single window agency Department. ii.(a) Stock verification of linen should Board’s letter Stock verification is carried out on a be carried out on a quarterly basis No.2009/M(C)/165/6 quarterly basis. ii.(b) At least 5% of new linen should dt.4.1.2010 Minimum 5 % of new linen checked be checked by SSE/Mechanical by SSE/C&W as per guidelines. for: (a) bundles being sealed and having batch nos., manufacturer’s name, year of manufacture, quantity, size indicated, (b) Linen items having marking of month / year of manufacture, Railway, etc. (c) dimensional check, colour, feel and workmanship, etc. ii.(c) Monthly report of inspections / This being ensured. Penalties as test checks of the linen washing applicable are deducted from bill and contractor’s premises by officers / payment is made after recovery of all supervisors, should be prepared penalties / dues. and payment should be made after recovery of all penalties / dues ii.(d) Enough buffer stock of linen to Stock of 2 days washed linen is last for 2 to 3 days is available available in depot. ii.(e) Life of linen is adhered to: Linen items are condemned as per Bed sheets : 12 months for khadi, recommended life of linen or on 24 months for poly vastra condition basis. Pillow cover/face towel : 9 months Pillow : 24 months Blanket : 48 months ii.(f) Committee nominated by DRM for A committee consisting of AME & linen condemnation on condition AMM has been nominated for linen basis Page 21 of 39 Coaching depot – TKPR, E. Rly. April 2012

S.N Item Clause Observation condemnation. iii. Specified frequency of Blankets are dry cleaned at one washing/dry cleaning of blankets month interval. and other linen items is adhered to 23.1 Passenger complaint on account Passenger complaints are analysed of linen is analysed and corrective and corrective and preventive action & preventive action is taken is taken. 23.2 Feedback on linen quality is Feedback system for quality of linen obtained through coach attendant from coach attendant is not as per RB’s guidelines adequate. CA is not reporting for linen quality in every trip. 24. Pest / Rodent Control i. Comprehensive contract covering Board’s letter Pest control is awarded to M/s PCI. pest / rodent control in coaches No.2010(M)/C/141/7 Vol.IV However, performance of pest control and rodent control in pit lines / dt.21.12.2010 agency to carry out pest control is not coaching depot yards awarded for satisfactory. 3 years under two packet system Depot has taken some additional initiative on its own for pest & rodent control management and passenger complaint on account pest / rodent reduced to 6 complaints from Oct’11 to Mar’12 against 11 complaints from Apr’11 to Sep’11. ii. All reserved (both AC and Non- All reserved coaches (both AC and AC) covered under contract, Non AC) are covered for pest control. unreserved coaches may also be covered as per requirement of Railways iii. Minimum frequency of pest The following frequency is adopted control treatment is adhered to : for pest control treatment: AC coaches / Pantry cars : AC coach – Weekly Fortnightly, Reserved Non-AC Non AC coach – Fortnightly. coaches : Fortnightly in first 3 Pantry car (AC) – Weekly. months, monthly thereafter, Unreserved Non-AC coaches : Bi- Pantry Car (NAC) – Weekly monthly Maximum tolerance +7 days, on account of operational exigencies, disturbance of rake links, etc. iv. Chemicals to be used (with brand Pest control management: names), concentration, dose  Through fogging / only spaying specified of chemicals or combination of both. 02 nos fogging machines are available. Spraying is followed by fogging of chemicals in each coach.  Chemicals used for pest control treatment of coaches: RoachEX (Propoxure), Deltamethrine, Deltamethrin Allethrin, Pest Seal (Lamda Cyhalothrin) v. Minimum frequency of rodent Depot has taken step for rodent control treatment is adhered to : control measure. Garbage from AC coaches / Pantry cars : during pantry cars are disposed before every Primary maintenance, arrival of trains in Yard. Dry sweeping Reserved Non-AC coaches : of Rajdhani coaches are done to Weekly Maximum tolerance +7 Page 22 of 39 Coaching depot – TKPR, E. Rly. April 2012

S.N Item Clause Observation days, on account of operational dispose of accumulated refuses from exigencies, disturbance of rake coaches. Refuses from OBHS links, etc. operated trains are also disposed at platform. This has minimised accumulation of garbage at depot during PM of rakes. In addition, all pantry cars are unloaded at platform or in Yard for effective cleaning. Regular rodent control measure is taken inside the depot. Rodent control measure has been adopted en-route also by providing glue board in the coaches under the berths (protection net provided along partition wall for keeping glue board). However, the following shortcomings noted for rodent control:  After dry sweeping of coaches, refuses are not collected and thrown on the pit lines.  Rodent control measure has not been taken by Howrah Division (Engineering/Medical) at platform area. vi. Personnel trained by certified Personnel for pest & rodent control training institutes deputed for are trained. pest/rodent control vii. Fumigation/mist treatment carried Pest control is being done in coaches out whenever coaches detached detached for IOH/POH attention. for IOH/POH. Pest/rodent control Pest/rodent control is carried out in carried out before inducting the off IOH/POH coaches before coach in service after IOH/POH inducting the coach in service. viii. In order to prevent cross All reserved coaches (AC and NAC) infestation, contractor may make of a rake are given pest control effort to treat all AC and all Non- treatment together. AC coaches of a particular rake together

ix. Stickers indication date of pest This is being ensured. control and next due date provided in doorway/toilet area x. Railways shall make effort to Pantry cars are detached from rake detach pantry cars from rakes once in a month to facilitate complete once a month (within reasonable vacation and intensive cleaning for tolerance) to facilitate complete thorough pest / rodent control vacation and intensive cleaning treatment for thorough pest / rodent control treatment xi. Broad methodology for measuring As per RB’s guidelines, pest the level of infestation of infestation is measured by providing cockroaches and rodents and bait (CMT). Record of pest and expected reduction over time is in rodent infestation is maintained. place 24.1 Passenger complaints on account This is being ensured. Passenger of pest are analysed and complaints are analysed for corrective action is taken. corrective and preventive action. Officer/ supervisors are deployed to collect feedback of pest / rodent Page 23 of 39 Coaching depot – TKPR, E. Rly. April 2012

S.N Item Clause Observation infestation in coaches. 25. Passenger amenities provided in Board’s letter Shop is not providing all amenities in various types of coaches as No.2006/M(C)/141/26 NAC coaches such as snack table, specified. dt.21.12.2006. bottle holder and magazine bag. These are found missing in sleeper coaches (NAC). 26. Infrastructure facilities – Appendix ‘E’ of Coaching TKPR depot has non standard deep Standard integrated modular pit manual pits. Only 3 deep pits of CAMTECH line have unified maintenance. CAMTECH report design have been constructed. 4 No.CAMTECH/M/99/Infra- more pits will be constructed. washing line/1.1 However, work is yet to be started. 27 Examination and repair Para 1009 of Chg manual practice in carriage maintenance depot for wheel sets and roller bearing 27.1 Wheel and axle Para 1009 a of Chg Total 108 wheel sets attended in manual 2011 -12 due to canted (37 cases), grease oozing (17 cases), Grazing with wheel (16 cases), warm and hot (nil cases) and other (cover, axle box wing) etc – 38 cases.

i) Wheel profile should be checked This is being ensured. with Tyre defect gauge to ensure the profile dimensions are within the permissible limits. ii) Limits for flat tyres This is being ensured. The limits for permissible maximum flat surfaces on tread for BG ICF coaches is 50 mm (reference Rly. Bd.'s Letter no. 83/M (N)/960/1/Vol I dated 15/18.3.99) iii) Guidelines for wheel inspection Supervisors are aware of various in open line depots (Ref RDSO wheel defects. However, CMI –K003 CMIK003) guidelines have not been displayed In addition to normal checks on shop floor and sick line. exercised on wheel condition

during primary/secondary maintenance of coaches, a detailed inspection of wheels should be done when the coaches are received in sickline for attention for either schedules or out of course attention. The wheels sets shall be inspected for the following conditions and action taken as indicated for each condition: a) Shattered Rim This is being ensured. b) Spread Rim This is being ensured. c) Shelled Tread This is being ensured. d) Thermal Cracks This is being ensured. e) Heat checks This is being ensured. iv) The defective wheel should be This is being ensured. sent to workshop for repairs after Page 24 of 39 Coaching depot – TKPR, E. Rly. April 2012

S.N Item Clause Observation entering in the maintenance card details of the work order and date of dispatch to workshop. v) No repairs, except wheel profiling This is being ensured. of wheel sets are permitted to be done in the maintenance depot.

27.2 Roller Bearing Axle Boxes Para 1009 b of Chg manual i) A coach should invariably be This is being ensured. detached from service for the following defects En-route detachment of coaches due i) Hot axle box to roller bearing failure during last 03 ii) Damaged axle box years is as under: iii) Damaged front or rear cover iv) Seized roller bearing Yr LHB ICF TOT v) Coach involved in accident, 09 – 1 1 2 derailment, fire, flood etc. 10 10 – 1 1 2 11 11 – 1 0 1 12

Each case of roller bearing failure is investigated for corrective and preventive action ii) Care should be taken not to keep This is being ensured. a coach fitted with roller bearing stationary for a long time. Coaches grounded for a long time should be shunted up and down

at regular intervals. Coaches fitted with roller bearing should be checked to ensure that :- i) No wash basin drain hole / discharge pipe is directly above This is being ensured. the axle box ii) The front and rear covers of the axle boxes are not damaged, This is being ensured. cracked or loose

iii) Clearance between axle box and wheel is such that the axle box does not bind against the This is being ensured. wheel. iv) Brake gear is properly adjusted to avoid possibility of brake binding This is being ensured.

27.2.1 Axle box is examined for grease This is being ensured. oozing out from rear cover and corrective action is taken. Total 41 wheel sets have been Concerned shop needs to be changed in 2011 -12 on account of advised for necessary corrective grease oozing out. and preventive action. 27.3 Axle box temperature Carriage Dte/RDSO letter Axle box temperature is measured by measurement by non contact type no. MC /AB dtd 21.08.09 non contact type temperature temperature measuring measuring instrument during rolling in instrument during rolling in examination. 6 nos non contact type examination: temperature measuring instrument Page 25 of 39 Coaching depot – TKPR, E. Rly. April 2012

S.N Item Clause Observation are available at Howrah PF. i) Temperature to be checked at This is being ensured. axle box top (crown) at front face of axle ii) If temperature is found above 800 This is being ensured. C, the affected coach will be detached. 27.4 Minimum permissible wheel RB letter no. 92/M diameter in ICH design BG (C)/137/2 Vol V dtd coaches. 25.1.11 i) Shop issue size of wheel set This is being ensured. Shop last should be 837 mm issue size in off POH coaches is 837 mm ii) Condemning diameter of the This is being ensured. Wheel wheel in service, measured at a condemning limit in open line is 825 distance of 66.5 mm from the mm. outer face of the rim shall be 825 mm.

28 Attention brake block hangers Carriage Dte/RDSO letter on ICF coaches – to avoid no. MC /ICF/B/D dtd failures 03.07.09 28.1 The new brake block hanger This is being ensured. should be procured as per revised spec C – 9808 Rev 2 and drg no. SK – 93286 Alt 5

28.2 Maintenance of brake gear This is being ensured. There is no rigging should be given as per hanger breakage case in 2011 – 12. guidelines circulated by ED/Carriage /RDSO vide letter no. MC /ICF/B/D dtd 03.07.09 29 Other items: 29.1 Changing of air brake hose pipe: Carriage Dte/RDSO letter Shop is changing air brake hose pipe Air brake hose pipe to be no. MC /APB dtd 19.02.09 in every POH. Open line has no MC changed in every alternate POH for new hose pipe. Serviceable hose attention. pipe from shop supplied to division. 29.2 Fire retardant items are provided RDSO spec and STR This is being ensured. in coaches as per RDSO specification. 29.3 FAC amenities are provided as This is being ensured. per guidelines circulated vide DG/Carrg/RDSO’s letter no. MC/CB/AC/BG dtd 28.04.10 29.4 Additional amenities / facilities in RB letter no. 2004 / M Snack table, magazine holders on GSCN type of coaches are (C)/165/16 dtd 29.03.05 partition wall and bottle /tumbler provided as under: holders are not provided in all  Snack table in each bay. sleeper coaches.  Mirrors in each bay  Magazine holders on partition wall  Bottle and tumbler holder 29.5 Maintenance of Duronto express: i) Pattern of maintenance for RB letter no. 2009/M This is being ensured for HWH - Duronto train as being followed (C)/141/2 dtd 25.08.09 NDLS Duronto Express (with Hybrid for Rajdhani trains with pit coaches). examination at both end should also be follwed.

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S.N Item Clause Observation ii) Rolling – in and rolling- out RB letter no. 2009/M This is being ensured. Super examination may also be (C)/141/2 dtd 25.08.09 checking report of officer is not conducted for each of the Duronto available. trains at the respective operational halts and also at the terminals during the journey. Such safety examinations of the Duronto trains may be periodically super checked at the level of officers. iii) Short distance Duronto with only RB letter no. 2009/M Short distance Duronto with AC/Non only AC / Non AC chair car may (C)/141/2 dtd 26.07.11 AC chair car is not maintained at be permitted to run on the extant depot. pattern for Shatabdi trains with a terminal attention at other end on platform / stabling line. A minimum 2 hrs may be planned at the non primary end to enable thorough attention to cleanliness, hygiene and passenger amenities at other end. iv) Cleaning of Vinyl wrapping on RCF’s letter no. MD This is being ensured. Duranto rake coaches Mild 22.151 dtd 09.02.10 detergent should be used with normal jet of water. High pressure water jet should not be directed towards Vinyl wrapping. 29.6 Attention of air springs ED/Carrg/RDSO’s letter no. MC/CB/MM dtd Procedure for rolling – in 09.09.2009 & Maintenance Hybrid coaches and Double Decker examination: manual of air spring for coaches are fitted with air spring. As train passes the nominated mainline ICF bogie Attention as recommended is given. point, C&W staff should watch out coaches vigilantly loose / hanging / broken RDSO/2009/CG/CMI-01, under gear parts of the coaches Sep’09 special attention should be paid to air springs in case of coaches provided with air springs at secondary suspension stage. It should be ensured all the air springs are in inflated condition by noting that the levelling valve lever is in horizontal position. In case it is not feasible to inflate the air springs of any particular coach, these should be isolated by air spring isolating cock and speed of train should be reduced to 60 Kmph or the coach should be detached. 29.7 Analysis of sick marking and en-route coach detachment i) Whether primary coach Primary detachment from coaches detachment is analysed and are being analysed by depot for corrective & preventive action taking CA & PA. Major contribution taken. Details of primary during 2011 -12 is wheel sets due to detachment for last 3 years to be root wear (27 %), grease oozing collected. (4.5%),tank leaky (10.4%), Brake cylinder (4.3%), Main/Lugg/Lav door (5.9%), Bk rigging (5.3%), draw & buffing gear (5.9 %)

Page 27 of 39 Coaching depot – TKPR, E. Rly. April 2012

S.N Item Clause Observation ii) Whether secondary detachment Secondary detachment from coaches is being analysed and corrective are being analysed by depot for & preventive action taken. Details taking CA & PA. Out of 17 cases of of secondary detachment for last detachment, 13 detachments 3 years to be collected. reported for Rajdhani rake due to secondary spring breakge.). Summary of secondary detachment during last three years is as under: Yr LHB/ ICF Total Duront o 2009 – 7 6 13 10 2010 – 6 3 9 11 2011 – 15 2 17 12 Secondary detachment is mainly on account of secondary spring breakage in LHB coaches (13 cases in 2011 – 12). iii) Whether en-route coach En-route coach detachment is detachment is investigated and investigated and necessary corrective & preventive action corrective and preventive action is taken. Details of en-route coach taken. detachment for last 3 years to be Summary of en-route detachment collected with investigation report. during last three year is as under: Yr LHB ICF Total 2009 – 1 4 5 10 2010 – 1 2 3 11 2011 – 1 0 1 12

29.8 Facilities for pit line and sick CAMTECH Maintenance line attention Manual for BG Coaches of i) Facilities available as per ICF design, Status has been indicated in CAMTECH guidelines as detailed 1st correction slip– Annexure - I in annexure – I to be observed. CAMTECH/2002/M/C/ CMM/1.0/CS-01(07.2006) 30 Passenger satisfaction 30.1 OBHS & escorting of trains i) Whether depot has provision of OBHS through outsourcing as per OBHS as per RB policy RB’s guidelines has been provided in guidelines. 14 important Mail/Express trains.

ii) Nos of Mail Express train in which In LHB Rajdhani (HWH – NDLS), escorting staff have been OBHS is provided by C&W escorting provided with cleaning staff by staff. depot. iii) Nos of Mail / Express trains in OBHS have been provided in 15 which OBHS have been provided. trains (14 through outsourcing and one train by depot) iv) Nos of Mail/ Express train in All major Mail/Express trains have which no staff from depot and been provided OBHS through Page 28 of 39 Coaching depot – TKPR, E. Rly. April 2012

S.N Item Clause Observation OBHS through contract have contract and escorting by depot. been provided. v) Average PSI for OBHS Av PSI is 94.2%. System exists to implemented rakes. Whether verify PSI by depot and deduction systems to cross verify PSI in has been made accordingly. OBHS provided train exist. 30.2 Whether depot has system to get System to get feedback of feedback of cleanliness, linen cleanliness, linen quality and pest quality and pest infestation of infestation of Mail/Express trains is Mail/ Express trains. Action taken not adequate. Regular feedback from by depot on the basis of feedback CA (coach attendant) in standard from passenger. format is not taken. However, Officers and supervisors have been deployed for on-board inspection to get the feedback of cleanliness, linen quality and pest infestation and OBHS performance. 30.3 Whether depot has system to Passenger complaints for last three analyse passenger complaint and years are as under: takes corrective action. Passenger complains for last Yr Pest/ Line Other Tot three years with action taken to be submitted. rode n s al nt 09 - 20 18 34 72 10 10- 34 50 53 137 11 11- 17 4 16 37 12

30.4 Whether depot has facility for Depot has awarded contract for mechanised cleaning of coaches. mechanised cleaning of 4 PM trains List of equipments and nos of only. Other trains are attended by rakes covered in every month to depot. Mechanised cleaning be submitted. equipments available in depot are not working. Cleaning through high pressure jet is available for Rajdhani Exp only. 30.5 Whether depot has facility for FAC and composite are provided with upholstery and carpet cleaning upholstery. Carpets have been either through in-house or through removed from coaches. Cleaning contract. Efficacy of cleaning to activity is being carried out through be observed. contract by a professional agency 30.6 Whether curtains are cleaned at Curtains are cleaned at one 15 days prescribed interval of 15 days as interval. per RB guidelines 30.7 Whether blankets are cleaned at Blankets were cleaned at one month one month interval as per RB interval.. guidelines 30.8 Compliance of CRB letter to CRB DO no. GM for sustainable image 2011/ER/6018 dtd makeover of the Railways: 28.07.11 i) Cleanliness of coaches: a) Ensure high standards of Cleaning standard in Rajdhani Exp is cleanliness in the coaching satisfactory. For other trains, outside maintenance depot particularly in area and toilets cleaning needs the washing line area. improvement.

Page 29 of 39 Coaching depot – TKPR, E. Rly. April 2012

S.N Item Clause Observation b) Action in respect of Depot has adopted collection and implementation of systems for disposal of leftover food and refuses collection bagging and disposal of from pantry coaches and OBHS leftover food from pantry cars and operated trains after arrival of train at coaches. station. c) Sustainable garbage collection Yard cleaning and garbage disposal and disposal system is carried out through contract. . d) Functional and efficient drainage Drainage is not adequate. Water to avoid water logging and dirt logging observed. collection e) Periodic fumigation of coaches Periodic pest control treatment is and high standards of cleanliness being done through fogging machine. in washing lines Cleanliness is being ensured in washing area. f) Monitoring the functioning of Functioning of OBHS is monitored. OBHS and CTS scheme. Officers and supervisors are carrying out on-board inspection to monitor performance of OBHS.

g) At the Zonal / Divisional level, Officers in SAG have been SAG / Selection grade officers by nominated at Zonal level under name and designation may be put “OYTS”. in –charge of important Mail/Express trains under “Own your train scheme (OYTS)” with responsibility being taken by the officers for the areas for which they have been nominated. ii) Quality of linen supplied on trains: a) Availability of clean and hygienic Linens are cleaned through linen to passenger through mechanised laundry. Depot has washing quality, adequate installed one mechanised laundry quantity, replenishment with new which cater requirement of 3500 linen on age / condition basis, use packets per day. Depot has total of washable blankets and appropriate quality of packing. requirements of 5,000 packets per day. Balance quality is washed through outsourcing in a mechanised laundry. 25% extra quantity is normally supplied in each coach. However, there is a space constraint for linen storage in ACCN coach of 2004 and earlier make. Regular condemnation is being done on condition / age basis and replenished with new linen. b) Commissioning of mechanised One mechanised laundry has been laundries at critical locations commissioned at depot and in dealing with large quantity of regular use since last 15 months. linens Total 3500 packets are washed in this laundry. c) System of packaging, storage and Packaging and storage is adequate. servicing of the linen to the Servicing to linen is being done by passenger must be streamlined. coach attendant of Electrical department & Commercial department. Page 30 of 39 Coaching depot – TKPR, E. Rly. April 2012

S.N Item Clause Observation 31 LHB coach attention: 31.1 Periodicity of periodic overhauls RB’s letter no. 95 /M (C)/ Depot has total holding of 78 LHB (POH) in designated workshops is 141 (LHB) dtd 22.08.06 coaches for Rajdhani service. being followed. IOH and POH attentions are given by Schedule Periodicity C&W Workshop, Liluah. IOH (Shop 18 months Periodic attentions (IOH / POH) as Sch I) / 5 lakh Km per RB’s guidelines are given. POH (Shop 3 yrs/ 10 Sch II) lakh Km D2 Schedule (Monthly attention) and POH (Shop 6 yrs / 20 D3 Schedule (six monthly attentions) Sch III) Lakh Km are given in rake. D3 schedule is not adequate as coach is not detached from rake for attention in sick-line. 31.2 Attention to following components Alsthom manual and OEM Contract for disc brake (including air are being given as per Alsthom manuals brake) attention in LHB coaches for manual guidelines and guidelines KB makes and FTIL make brake circulated by RDSO. system expired. Depot is carrying out  Phonic wheel / speed maintenance attention of KB and sensor.  Dump valve FTIL make disc brake system  Earthing device. through in-house. Population of KB  Control arm and FT make disc brake system is  Dampers as under  Primary vertical KB make: 30 dampers. FTIL make: : 48  Secondary vertical Attention for phonic wheel and speed dampers sensor is given as per recommended  Yaw damper. frequency.  Secondary lateral damper Earthing device is attended through a  Primary and secondary contract on OEM and all earthing springs devises are in working condition.  Disc brake attention Depot is attending CDTS in-house.  CDTS (Controlled Spares are procured by depot from discharge toilet system) OEM. All CDTS are in working condition. Depot has rigged up a CDTS testing bench.

Depot has received following dampers against indent placed on RCF as well as against warranty replacement: : Primary dampers: 140 Secondary vertical: 68 Lateral dampers: 50 Yaw dampers: 20 31.3 Wheel sets and CTRB attention at depot: i) The wheels sets shall be Para 1009 a (iii) of chg This is being followed. Supervisors inspected for the following manual are aware of various wheel defects. conditions and action taken as However, CMI –K003 guidelines indicated for each condition: have not been displayed on shop  Shattered Rim floor and sick line.  Spread Rim  Shelled Tread  Thermal Cracks  Heat checks

Page 31 of 39 Coaching depot – TKPR, E. Rly. April 2012

S.N Item Clause Observation ii) Wheel profile should be checked Para 1009 a (i) of chg This is being followed. with Tyre defect gauge to ensure manual the profile dimensions are within the permissible limits. Coaches with wheels having thickness and profile worn below condemning limit should not be allowed to continue in service and the coach should be marked sick for change of wheels in the sick lines. iii) The limits for permissible Para 1009 a (ii) of chg This is being followed. maximum flat surfaces on tread manual for BG ICF coaches is 50 mm (reference Rly. Bd.'s Letter no. 83/M (N)/960/1/Vol I dated 15/18.3.99)

iv) System is available for rolling–in Carriage Dte/RDSO letter Rolling–in examination is being examination at terminating station no. MC /AB dtd 21.08.09 carried out at HWH station. Axle box and axle box temperature is temperature is measured with non- measured with non contact type contact type temperature measuring temperature measuring equipment. Corrective action is taken equipment and corrective action is taken for wheel sets with high for wheel sets with high temperature. temperature. 3 wheel sets of LHB coaches changed due to difference of temperature above 200C v) Last shop issue size (865 mm) This is being followed. and condemnation limit for wheel sets (845 MM) as stipulated is being followed. vii) Presently the Traceability of wheel sets is ensured. refurbishing/overhauling of LHB Attention as stipulated is given for bearing is being done at an attention of CTRB at an interval of interval of 1.2 million km. To 1.2 Million Km. ensure attention of CTRB’s as

well as UST of axle, depot should have proper identification of Wheel sets are cannibalised during wheels sets. In case wheel sets maintenance and wheel sets sent to are interchanged then traceability shop when due for CTRB attention of wheel sets and timely attention (at 3 years interval). It is observed of wheel sets exist in the depot. wheel sets with life of more than 2 years are in service at depot without UST of axle. As per guidelines circulated by DG/M&C/RDSO vide letter no. M&C/NDT/1/8, ICF axle need to be given UST at one year interval. No such guidelines have been circulated for LHB wheel sets. Presently LHB axle is attended for UST when wheel sets touch the workshop. viii) Depot should not permit wheel Wheel sets with flake is not permitted sets with flaking in service. in service. Adequate spare wheel sets are available in depot. ix) Whenever coach is sent to shop This is being ensured. Details for POH/IOH or non schedule provided to shop. attention, details of wheel sets with regard to CTRB attention Page 32 of 39 Coaching depot – TKPR, E. Rly. April 2012

S.N Item Clause Observation should be furnished to shop. Whether system exist in depot. Similarly when loose wheel sets are sent to shop, details of wheel sets with regard to CTRB attention should be furnished to shop. x) Grease oozing out is checked With existing system, grease oozing during attention at depot and out can be checked from front seal corrective action is taken only when front cover is opened. This accordingly. being checked during D2 schedule as front cover is opened for attention. For checking grease oozing out at rear grease seal, bottom control arm to be taken out. Checking of grease oozing out is not done for rear end seal at depot even in D3 schedule. xi) Drain holes of control arm should This is being eneured.. be regularly cleaned to prevent its choking. xii) Checking of mounting bolts of Mounting bolt is tightened regularly control arm is being done during during PM. primary maintenance. 31.4 Phonic wheel/Speed censor OEM guidelines i) M8 size screw to IS 1367 Pt.III This is being ensured. class 10.9 along with spring washer to the IS 3063 type-B should be used for securing phonic wheel. LOCTITE 243 or equivalent glue should be used to ensure rigid connection between internal and external thread. The Phonic Wheel screws should be tightened with 21N-m torque. ii) The clearance between the This is being ensured. phonic wheel and speed sensor should be 0.9 to 1.4 mm in case of KB make WSP and 1 to 2mm in case of FTIL make WSP. This gap should be checked in quarterly schedule or whenever required. iii) The phonic wheel and speed This is being ensured. sensor should be procured through OEMs/OEMs’ approved sources only. M/s KB and M/s FTIL are OEM of this item. iv) Speed sensors’ cables should be This is being ensured. properly connected and should be without any loose strands. 31.5 Dump Valve OEM guidelines This is being ensured. Proper Dump Valve connection and ensuring that no dump valve leaks during brake application. 31.6 Earthing Device OEM guidelines Earthing device of most of the All earthing devices are working. coaches should be functional. It Earthing devices are maintained consists of non ferrous through AMC on OEM. components (approx 2kg weight) which are theft prone. Loose Page 33 of 39 Coaching depot – TKPR, E. Rly. April 2012

S.N Item Clause Observation fasteners, in case of theft attempts for non-ferrous items, mounted inside of axle box housing, can damage CTRB. Most of the earthing devices with Earthing devices with connecting connrecting wires/cables were wire are available. missing. Junction box in broken/damaged Junction box is in good condition. condition. 31.7 Disc brake attention: OEM guidelines i) Brake pads are renewed on Brake pads are renewed on condition condition basis and adequate basis. spare is available at depot ii) Whether regular attention of Brake callipers of KB and FTILO brake calliper is being ensured. make are attended by depot as AMC with FTIL expired in Mar’11 and with KB expired in Mar’12. iii) Whether regular attention is being Regular attention is given by depot given to disc brake system through in-house. However, WSP is through AMC or in-house not working in 07 coaches. attention. Availability of spares for disc brake system is hampering regular attention of disc brake system. 31.8 Whether guidelines circulated by Carrg Dte/RDSO letter no. Depot is not aware of Guidelines RDSO for CBC equipped coaches MC/BLB/CBC dtd 22.05.08 issued by RDSO. However, at are being followed. present coaches sent to and received from platform with full brake in working to avoid rolling of LHB rake. 31.9 Attention of side buffer: Carrg Dte/RDSO letter no. This is being ensured. Length of Length of side buffer of CBC MC/BLB/CBC dtd 17.02.08 buffer is maintained for ASF make equipped SLR (FV & LV) is and FTIL make as under: maintained to 635 mm as per FTIL make – 650 mm RDSO drawing no. SK - 98145 ASF make – 635 mm

Page 34 of 39 Coaching depot – TKPR, E. Rly. April 2012

Annexure - I Standard facilities in Carriage Maintenance Depots (Ref : CAMTECH Maintenance Manual for BG Coaches of ICF design, 1st correction slip– CAMTECH/2002/M/C/CMM/1.0/CS-01(07.2006)

Classification of depots

Classification No. of coaches based Minor Depot Below 100 Medium Depot 100 to 250 Major Depot Above 250

TKPR depot/Howrah is major depot as coach holding is 740 coaches.

Availability of Machinery and Plant

Minor Medium Major Description Observation Depot Depot Depot U/floor wheel lath - - 1 01 no available Whiting jacks (5 Nos.) - 1 set 1 set 16 nos EOT crane 20T - - 1 25 T carne is under installation. Coach Shunter - 1 2 Available under traffic department. Welding Plant 1 2 4 22 sets Gas Cutting Equipment 1 2 2 Available Vacuum Exhauster 1 2 2 Not required. 360 CFM – 01 no. Air Compressor 30 cfm 1 2 2 500 CFM – 3 nos. Portable Vacuum Testing Equipment - 1 1 Not required Portable Air Compressor - - 1 Not available 2T Tram beam hoist 1 1 2 OH hoist (3T) – 1 no Sewing machine - 1 1 02 nos Truck 10T - - 1 Not available Light Coml. Vehicle 1 1 1 Not available Fork lift truck - - 1 04 nos Lister truck 1 1 2 05nos Car Washer - 1 1 Available

Page 35 of 39 Coaching depot – TKPR, E. Rly. April 2012

Minor Medium Major Description Observation Depot Depot Depot Portable Trolley Light 2 4 Not available Cotton waste soaking plant 1 1 1 Not required. Wood cutting saw machine - 1 1 Not required Hand shearing machine - 1 1 Available Portable Furnace 1 1 2 Available Centre Lath - - 1 Available Bogie Manipulator - - 1 Not available Ultrasonic Testing Apparatus 1 1 1 Not available Tool post Grinder - 1 1 Not available Vacuum Cleaner 1 2 3 Not available

Pressure Jet Cleaner 1 2 4 Not available Tools a. Pneumatic Hand Tools i. Grinder 1 1 2 Not available ii. Drill 1 1 2 Not available iii. Chipper / Buster - 1 2 Not available iv. Riveter - - 1 Not available b. Electric Power Tools i. Pop Riveting Gun - 1 1 Available ii. Drill - 1 1 Available iii. Bolt Tightner - - 1 Available c. Hand Tools As required Available d. Test Bench i. Water Tank Test Rig - 1 1 Not available ii. D.A. Valve Test Bench - 1 1 Not required. iii. Vac. Cyl. Test Bench - 1 1 Not required. iv. Slack Adjuster Test Bench - 1 1 Not required. v. DV Test Bench - 1 1 DV testing done at shop. RTR – 10 nos vi. Air brake single coach test rig - 1 1 SCTR – 04 nos e. Office Equipment i. Computer system 1 1 1 Available ii. Plain Paper Copier 1 1 2 02 iii. Telefax 1 1 Available

Page 36 of 39 Coaching depot – TKPR, E. Rly. April 2012

Annexure - II Emergency materials required for platform (C&W) office Sl. Items Required Observation 1 Screw Coupling complete ( 75 t ) 1 no. Available 2 Draw Hook ( ICF- Enhanced capacity) 1no. Available 3 Draft cotter with 'U' pins 1no. Available 4 Draft link complete 2 sets Available Equalizing Stay rod with pins ( Non-modif. & Available 5 1 set each Modif.) 6 Anchor link with securing studs 1 set Available 7 Truss Bar Hanger with Pins & Cotters 2 sets Available 8 Bolster suspension Link (Stirrup Link) with Pins & Available 2 sets Stones Axle Box Face Cover (ICF) with securing nuts & Available 9 2 sets Pins 10 'O' Ring 2 nos. Available 11 Grease Servogen 4 kgs. Available 12 Adaptor (BF+FP) for by-passing 2 sets Available 13 Angle cock 2 nos. Available 14 Dummy Flange (A/B) 2 nos. Available 15 M.U. washer 10 nos. Available 16 Teflon Tape 1 no. Available 17 Portable Air Pressure Gauge 1 no. Available 18 Pressure Gauge BP & FP 2 each Available 19 BP & FP Air hose 2 each Available 20 Guard Emergency Application Valve 2 nos. Available 21 Wooden Plug (various sizes) 10 nos. Available 22 Wooden wedge 4 nos. Available 23 G.I. wire Adequ. Qt. Available 24 Buffer bolts (20x120 mm.) 8 nos. Available Page 37 of 39 Coaching depot – TKPR, E. Rly. April 2012

25 Push cock 5 nos. Available 26 Spl. Jack for changing Eq/Stay rod 1no. Available 27 Slide wrench, Pipe wrench-24'' 2 nos Available 28 Hydraulic Jacks 2 sets Available

Annexure – III Details regarding coaching depot Depot name and division:

1. Coach Holding Mail/Expresses coaches with conventional coupling 604 Mail/Expresses coaches with CBC coupling NIL Rajdhani/Shatabdi coaches (conv) 16 LHB coaches (Rajdhani/Duronto) 75 Hybrid coaches for Duronto 28 Double Decker 17 Grand Total 740

2. Maintenance attention of at depot

Mail Express trains PM with RTM at other end 13 PM with SM at other end 5 RT attention (other base) 5 RT attention (own base) 2 SM attention of other base 1 Total attention 26

3. Pit line attention 24 coach pit with catwalk and high pressure water 3 CAMTECH design deep pits have been jet facility/watering facility at per CAMTECH’s constructed. However, high press jet facility has guidelines not been provided. 24 coach pit facility with catwalk and washing 04 nos apron Less than 24 coach pit facility with catwalk and 08 nos washing apron Page 38 of 39 Coaching depot – TKPR, E. Rly. April 2012

Stabling line for round trip attention and stabling of rakes: Stabling line with 24 coach length facility NIL Stabling line with less than 24 coach facility 03 nos. Compressed air with reservoir and air 4 nos compressors (500 CFM – 3 nos. and 360 dryer/moisture trap facility with test rig (RTR) CFM – 1 no.) are available with air dryer facility. Facility for welding at Yard attention Facility for welding at Yard attention is available. Night maintenance facility with overhead/pit light as Deep pit lights are not working. Tube Lights are per CAMTECH’s guidelines provided under catwalk in 03 pits. Minor lamps are used for pit attention. Portal lights have been provided in 03 deep pits. Overhead lights have been provided for general illumination. Night maintenance facility is available in 03 pits only. 4. Sick line facility:

Coach lifting facility with overhead crane NIL Coach lifting facility with JMP jack/hydraulic jack 16 nos. Total coach accommodation  With pit attention 4 coach  Without pit attention 6 coach Facility for compressed air with test rig (SCTR) 04 nos. Availability of hydrant water for overhead tank attention Water hydrant is available but testing facility to carry out hydraulic testing of repaired water tank is not available. Welding facility Available

5. Facility for rolling-in/rolling-out examination with adequate lighting arrangement (for attention during night) as per CAMTECH’s guidelines: Deep pit lights are not working. Tube Lights are provided under the catwalk. Minor lamps are used for pit attention. Portal lights have been provided over 03 deep pits. Overhead lights have been provided for general illumination.

6. Availability of staff for coaching maintenance as per Yard stick: Availability of manpower vis-à-vis requirement as per yard stick (bench marking norm) is as under:

Requirement as per Yard Shortfall Activity Availability stick (bens marking norm) /Excess For cleaning activity 304 290 -14 For under-gear attention 354 335 -19 For sick-line activity 53 49 -4 For ancillary work 135 109 -26 Page 39 of 39 Coaching depot – TKPR, E. Rly. April 2012

7. Training status of supervisor and staff – Overdue training for supervisors – 109 (Due: 116 & training given: 7) and overdue artisan for refresher course - 81. Training of supervisor is given at STC/KPA. Depot has a good facility of Divisional Training school for training of Artisan Staff.

8. Availability of critical/ safety stores and storage system: Safety list has been published by RB. Depot is yet to reconcile safety store as per RB’s guidelines. Stock of safety items as per present list is available. Stacking is adequate. There is crisis of composite brake block, secondary outer spring for LHB coaches, speed sensor for LHB coaches and NFTC packing ring at Depot.

9. Availability of coaches as per rake link with maintenance spare: Against requirement of 613 coaches, total available stock is 740. (Maintenance spare as per yard stick is available).

10. Bottlenecks / limitations of system / depot:

 Non standard Deep pits: Pits available were of non standard design without cat-walk. Only 03 deep pits of CAMTECH design with Catwalk have been constructed.  Inadequate spacing between two pits.  Curved Maintenance Line  Inadequate drainage system.

11. Safety performance record:  There is no derailment / accident on C&W account.  There is one en-route detachment of coach in 2011 -12.

12. Performance of critical spare:  Dampers fitted in LHB caches become defective due to oil leakage.  Rubber Bush fitted in damper cracked / perished during service.

Page 40 of 39 Coaching depot – TKPR, E. Rly. April 2012