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12185666 03.Pdf Agenda Indian Railways & RITES Overview Indian Railways Safety Perspective Indian Railways: Preventive Maintenance – Diesel Locomotives Perspectives on Safety Preventive Maintenance – Wagons Preventive Maintenance – Coaches Presented by: Puneet Kumar, Group General Manager, RITES RITES – Credentials 27 September 2012 00 01 Indian Railways – Nation’s Lifeline Indian Railways – System Performance Key Statistics for the Indian Railways System Performance – Overview Parameter # Comments # Parameter 1950-51 2010-11 % increase 1 Route length (km) 53,596 64,460 20 64,460 route-km Track length One of the world’s longest railways 2 Passengers originating (million) 1,284 7,651 496 114,000 track-km 3 PKM (billion) 67 979 1,371 Employees 1.33 million Largest employer in India 4 Lead (km) 52 128 147 Revenues USD 19 billion One of the largest railways 5 Freight originating (million tonnes) 93 922 891 6 TKM (billion) 44 625 1,318 Daily freight loading 2.5 Mn tonnes 35% of national freight 7 Lead (km) 470 679 44 Passengers 21 Mn daily 20% of market 8 Locomotives 8,209 9,213 12 9 Coaching stock 19,628 53,220 171 10 Wagons 205,596 229,381 12 Indian Railways (IR) is not just large – it is also successful 11 NTKM/wagon day 710 9,247 1,202 IR has 230,000 wagons, 53,000 coaches, 9,200 locos & 7,000 stations More than 13 fold increase in passengers and freight with only marginal IR is a profitable organization despite India’s low fare policy increase in network & rolling stock IR has a 159 year old legacy in India and caters to the bulk of the country’s Modernization, change of traction, concentration on trainload traffic, infrastructure requirements (unlike developed countries) constant optimization required to ensure successful performance 02 03 Indian Railways – Over the Years Indian Railways – Structure Indian Railways – History Indian Railways – Key Characteristics Has 1½ centuries of development of systems , rules and IR is entirely state owned and managed technology from: under Ministry of Railways, Govt. of India Steam to diesel to electric traction It is divided into 16 territorial zones and further subdivided into 68 territorial divisions Wooden to steel to CST 9 to pre-stressed concrete sleepers Largely self sufficient with a number of Rail Bhavan production units manufacturing locomotives, Non interlocked to standard III interlocking to route relay coaches, equipment, spares, etc – less than interlocking to CTC 4% of spares are imported Copper wire fixed line communication to mobile telephony Incorporates a number of training Manual train control charting and reservation to the world’s establishments and public sector units under largest computerized passenger and freight system its aegis RITES – oldest of the PSUs – set up in RITES Bhavan Improvement in systems & rules spans entire gamut of railways 1974 for export of rail consultancy 04 05 RITES RITES – Presence in Africa RITES – Overview RITES – Projects in Africa 38 years of experience of rail consultancy, both in India and abroad; owned by Ministry of Railways, Government of India Resource base of nearly 3,000 staff, including over 1,400 specialists of high professional standing in fields of engineering, maintenance, management, etc Specialises in providing multidisciplinary consultancy and training in transport and infrastructure sectors Worked with World Bank, African Development Bank, Asian Development Bank, UNIDO, UNDP ISO 9001-2008 accreditation Operational experience in over 62 countries in Africa, South East Asia, Europe, Middle east and Central and Latin America 06 07 Agenda Indian Railways – Safety Safety Requirements and Dependencies Indian Railways & RITES Overview Indian Railway operates a vast and Scope of safety Indian Railways Safety Perspective dense network – 16,000 train runs Hardware: Fixed infra (S&T, daily sharing same set of tracks tracks, OHE) & movable rolling Preventive Maintenance – Diesel Locomotives City networks are even more intense infra (locos, wagons, coaches) Preventive Maintenance – Wagons – e.g. Mumbai local train network Software: Inspection systems, Highest passenger density of train running procedures, etc. Preventive Maintenance – Coaches any urban system in the world 2,500 daily trains carrying 7 Safety Dependencies RITES – Credentials million passengers average daily Working of railway staff 450 km of track covered Discipline, rules and procedures Track, rolling stock, signals, Safety is of paramount electrical equipment importance Quality of spares Quality of maintenance, etc. 08 09 Indian Railways – Key Drivers of Safety Indian Railways – Safety Organization Key Drivers for Safety in Indian Railways Safety Organization – Structure 1 Archaic systems such as semaphore signals (1870), ball Chairman (Overseas Safety) Signaling and token system (1920) Member Traffic (MT) Interlocking Developed into Modern Signaling System with features Board Level such as route relay interlocking, centralized train control etc Advisor/Safety 2 From Morse Telegraphy to optical fibre based voice and 5 Directors (Safety Directorate) Communication data communication Protocols Mobile Radio (between Guard & Driver) Emergency Communication by Satellite Phones General Manager 3 Chief Safety Officer Shift to modern tracks – long welded rails; PSC sleepers Zonal Level Track with fasteners; and modern maintenance methods – use Junior Administrative Grade Officers Development of track machines, portable accelerometers , track recording cars and similar sophisticated gadgets from the main departments 4 Locomotives – ALCO, GM, ABB Rolling Stock Coaches & Wagons – 4W stock replaced by reliable and DRM with Sr. DSOs/DSOs Improvement stable 8W stock; air brakes; standardization of maintenance SS/Asst. Scale officers facilities; preventive maintenance Divisional Level 5 Safety counsellors Human Resource Use of multiple modes/mechanisms to ensure development Supervisors – lateral recruitment; trainings, aptitude tests, aligned key Development performance indicators and incentives 10 11 Indian Railways – Role of Safety Accident Classification Organization Safety Organization – Roles & Responsibilities Accident Classification – Overview 1 Reporting and enquiry into accidents Collision / Derailment / Fire in trains / Level Train Accident Crossing Accidents / Others/Miscellaneous Implementation of recommendations of CRS and enquiry reports Reported through Safety Wing Compilation and analytical reviews of trends of accidents and remedial action 2 Monitoring of disciplinary action and adequacy of punishment Indicative SPAD / Averted Collision Liaison with other departments for safe working of maintenance and Accident Reported through Safety Wing operational practices Safety and ambush checks of functioning of operational and maintenance 3 Cases of train wrecking / sabotage, Theft / Robbery, Fire / explosion in railway premises, departments Unusual Accident floods / breaches, run over cases etc., Signal sighting committees and rectification of deficiencies noticed Reported through Security Wing Preparation and circulation of safety circulars, posters and bulletins etc. 4 General failure of equipment – locomotives, Regular counselling and monitoring of operating and maintenance staff Equipment rolling stock, tracks, signaling etc., Failure Co-ordination for relief and restoration during accidents Reported through Punctuality Wing 12 13 Accident Response & Relief Indian Railways – Safety Accident Response & Relief – Overview Safety Perspective – Summary First response to accident Equipment to provide relief Safety is a continuous and ongoing exercise Convey information 115 breakdown trains including 57 Indian Railway has detailed procedures to deal with accidents, Medical assistance 140 tonne cranes conduct time bound enquiries and suggest remedial actions Passenger assistance 185 accident relief trains including 10 SPARTs Focus on safety is evident in the importance placed upon Organise alternative transport 174 accident relief medical vans training of: Security Hydraulic re-railing equipment and Running staff – drivers, assistant drivers and guards and Communication hydraulic rescue devices in ARTs Send relief to site Train passing staff – station masters, cabin men, points Special trained manpower to attend men , etc. Preserve clues and evidence to accidents Joint measurements Capacity to mobilize special trains for evacuation The best safety device is a careful man 14 15 Indian Railways – Locomotive Agenda Preventive Maintenance Locomotive Preventive Maintenance – Objective & Structure Indian Railways & RITES Overview Key Objectives IR Resources Indian Railways Safety Perspective 1. Improved availability Satellite Diesel Sheds (T20 Preventive Maintenance – Diesel Locomotives measured in terms of &T40 schedules) Preventive Maintenance – Wagons ineffective locomotives over Homing Diesel Sheds (M4, 24 hrs or outage for freight M8, M12 & M24 schedules) traffic on hourly basis Preventive Maintenance – Coaches Diesel Workshops (Periodic RITES – Credentials 2. Enhanced Reliability (Kms per Overhaul – 8 Years or one locomotive failure) million kms, whichever is 3. Higher resource productivity earlier) 4. Lower costs Locomotive Re-building/Mid- 5. Safety life Rehab.Unit 16 17 1. Maintenance Systems & Concepts Locomotive Preventive Maintenance – Consolidation of Maintenance Activities Major Thrust Areas Major Thrust Areas for Preventive Maintenance Overview 1 Maintenance Refers to concepts such as consolidation of Important to consolidate maintenance activities because: systems & maintenance
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