(For official use only) (Govt. of India) (Ministry of Railways) Draft Hand Book on Integrated Rolling Stock Depot IRCAMTECH/2017/M/GWL/IRS DEPOT/1.0 April- 2017 MAHARAJPUR, GWALIOR--474005 Handbook on Integrated Rolling Stock Depot Page 1 of 61 PREFACE As per instructions from Railway Board, & CME conference item No. 1.10, CAMTECH to prepare report on the “Handbook on Integrated Rolling Stock Depot”. The Handbook has been prepared based on contents taken by nominated committee for the purpose and visits of Coaching depots, MEMU sheds & DEMU sheds and interaction with concerned officers / supervisors & concerned depots/divisions for further course of actions. Handbook has been prepared by CAMTECH with the objective to provide guidelines for standardization of infrastructure and maintenance practices of MEMU/DEMU and Mainline Coaching Stock in the Integrated Rolling Stock (Coaching) Depot. It is clarified that this handbook does not supersede any existing procedures and practices laid down in the maintenance instructions issued by manufacturers or by Railway Board/RDSO. April, 2017 (K.P.Yadav) Place: CAMTECCH/GWL Director / Mechanical CAMTECH/Gwalior Handbook on Integrated Rolling Stock Depot Page 2 of 61 Contents SN Description Page No. PART-A 01. Constitution of committee 4 02. Terms of reference of the committee 4 03. Details of visits made by the CAMTECH 4 04 Data collection:- 4 4.1 Dimensions of various coaches 4 4.2 Weight chart of various coaches 5 4.3 Arising out of course repairs 5 05 Discussion on the Terms of References 5 5.1 To suggest the infrastructure and facilities required in the new and existing 5 integrated rolling stock coaching depots – (i) Short Term Measures 5 (ii) Long Term Measures 6 5.2 To suggest short term and long term measures for the integration of Trip, 6 Minor and Medium repairs of MEMU/DEMU trains in the mainline coaching depots of IR. 5.2.1 Pit line infrastructure 6 5.2.2 Sick Line Infrastructure 8 (i) Machines and Plants required in the rolling stock depots 9 for maintenance of MEMU (ii) Machines and plants required in the Rolling Stock 9 Depots for maintenance of DEMU 5.2.3 Record keeping 9 5.3 To suggest ways to utilize the released capacity in the existing sheds/Depots 9 for MEMU / DEMU for carrying out major repairs of MEMU/DEMU rakes. (i) Maintenance of MEMU rakes in existing DEMU sheds (ii) Maintenance of DEMU rakes in the existing MEMU sheds. 9 9 5.4 To Review the various maintenance schedules and their periodicity for MEMU, 10 DEMU & main line coaching stock and suggest ways for rationalizing the same. (i) Recommendations for various maintenance Sch.in Annexure-B 11 5.5 To suggest ways for the multi-skilling of staff and reducing the number of 12 cadres engaged in the work of maintenance of MEMU/DEMU/Main line coaches by appropriate training and other methods. (a) Actual staff deployment in DEMU/MEMU sheds 12 (b) Multi-skilling of staff and merger of trades 13 06. Recommendations of the committee 14 07. Lay out drawing of Integrated Coaching Depot 17 08 Annexure-A-Observations during the visits of DEMU/MEMU sheds 20 PART-B 09 Standardisation of Tool Kit and Gauges for Pit Line Maintenance 24 10 Items for Rolling-in/Rolling-out examinations for ICF & LHB coaches 49 11 Check list for inspection of Coaching depot 55 12 Check list for inspection of DEMU 59 13 Check list for Super checking of DEMU 61 Handbook on Integrated Rolling Stock Depot Page 3 of 61 1.0 Standardization of Infrastructure and maintenance practices of MEMU/DEMU and Mainline Coaching Stock in the Integrated Rolling Stock (Coaching) Depot. Vide Railway Board’s letter No. ERB-I/2016/23/67 dated 09.12.2016, a committee was constituted consisting of DME/Chg., Railway Board (Convenor), DEE(G), Railway Board, DME(Traction), Railway Board & Director/Mech/CAMTECH on the subject of “Standardization of Maintenance Infrastructure and practices of MEMU/DEMU and mainline coaching stock in the integrated Rolling stock coaching depots”. 2.0 Terms of Reference of the Committee: a. To suggest short term and long term measures for the integration of trip, minor and medium repairs of MEMU/DEMU trains in the Mainline Coaching Depots of IR. b. To suggest the infrastructure and facilities required in the new and existing integrated Rolling stock coaching depots. c. To suggest ways to utilize the released capacity in the existing sheds/depots for MEMU/DEMU for carrying out major repairs of MEMU/DEMU rakes. d. To review the various maintenance schedules and their periodicity for MEMU, DEMU and Mainline Coaching stock and suggest ways for rationalizing the same; e. To suggest ways for the multi-skilling of staff and reducing the number of cadres engaged in the work of maintenance of MEMU/DEMU/Mainline coaches by appropriate training and other methods. 3.0 Details of Visits made by the Committee: The following sheds/Depots have been visited for analysis of requirements for integrated maintenance of Coaches, DEMU & MEMU. (i) Diesel / DEMU Shed / SSB / NR on 04 & 07.01.2017 (ii) DEMU maintenance Depot/Medta Road/NWR on 05 & 06.01.2017. (iii) EMU Car Shed, Ghaziabad/NR on 07.01.2017. (iv) MEMU maintenance shed/Saharanpur/NR on 19.01.2017 The observations of the committee during these visits are placed at Annexure A 4.0 Collection of data 4.1 Dimensions of various types of Rolling stock SN Type of stock Width Length Height 01 LHB Coach (Except DD) 3240 mm 24000 mm 4265 mm 02 LHB Double decker 3050 mm 24000 mm 4366 mm 03 ICF Coach 3245 mm 22297 mm 4025 mm 04 BEML coach 3250 mm 22296 mm 3991 mm 05 DEMU (DPC) 3245 mm 21417 mm 3886 mm 06 MEMU (Motor Coach) 3245 mm 21417 mm 4255 mm 07 MEMU (Trailer Coach) 3245 mm 21337 mm 3886 mm Handbook on Integrated Rolling Stock Depot Page 4 of 61 4.2 Weight Chart of various Coaches: Type Motor/Trailer Tare weight Pay load Total Weight of stock DEMU Driving Power Coach(DPC) 72.79 T 07.99T 80.78T 1600 Trailer Coach (TC) 36.25 T 21.51T 57.76T HP Trailer Coach Vender (TCV) 35.20 T 22.75T 57.95T MEMU Motor Coach 59.00 T 2.42T 71.42T Trailer Coach 35.00 T 21.12T 56.12T LHB LHB Coach 44.50 T Double Decker Coach 49.53 T ICF ICF Coach 50.00 T 03.68 T 53.68 T Coach 4.3 Arising of out of course repairs per year: S.N. Item EMU Car MEMU DEMU DEMU Remarks Shed/GZB Maintenance Shed NWR Shed/SRE SSB 01 Traction 55 to 60 12 per year Not avl Not done motor change 02 TM Bearing 18 to 20 5 per year Not avl Not done change (both type) 03 Wheel 05 N/A N/A N/A Change 04 Main 9-10 N/A N/A N/A N/A Compressor Change These items shall be provided as a Unit exchange spare in the sick line of the integrated Rolling Stock Depot. 5.0 Discussion on the Terms of Reference: 5.1 To suggest short term and long term measures for the integration of trip, minor and medium repairs of MEMU / DEMU trains in the Mainline Coaching Depots of IR. The committee has listed the “Short term” and “Long term” measures as follows: A. Short term measures: i. DEMU and MEMU rakes can be based at the nearest and most suitable Rolling Stock (Mainline) Depot for carrying out trip schedule. Handbook on Integrated Rolling Stock Depot Page 5 of 61 ii. Each Railway where DEMU and MEMU rakes are running / maintained shall identify one or two such Rolling Stock (Mainline) Depots where the trip maintenance of DEMU and MEMU rakes can be carried out. iii. Few pit lines shall be nominated for the trip maintenance of MEMU / DEMU. It is preferred that the shorter length pit lines, in case available, shall be nominated for the purpose. This shall avoid wastage of pit line capacity. iv. Necessary facilities as listed in Para 5.2 shall be created at these depots. v. These pit lines shall be top wired and made fit for the maintenance of MEMU / DEMUs. Proper system for isolation of the OHE shall be provided. The feasibility of providing re-tractable OHE, which is automatically slewed away from the rake during its maintenance, shall be explored. A similar system is available in the pit lines of DMRC (Sarita Vihar depot). vi. Both Railway and Contractor staff working in the pit lines shall be trained and sensitized for taking precautions while working on the rakes on the adjacent lines so as to prevent any possibility of electrocution (such as not directing the high pressure jet towards the OHE, etc.). Regular safety drives shall be carried out in order to ensure proper isolation of OHE and observance of precautions by both Railway and Contractor staff. Meticulous records of the training and safety drives shall be maintained. vii. The rake links of DEMU/MEMU trains may be planned in such a manner that each rake is brought to the Integrated Rolling Stock (Coaching) Depot once every 10 days for trip maintenance. B. Long term measures: i. The monthly schedule for DEMU and 45 days schedule for MEMU shall be carried out in the integrated Rolling Stock (Mainline) Depot. Based on the expertise acquired, practical experience gained and infrastructure created, this may be extended upto 6 / 9 monthly schedules for MEMU / DEMU in future.