Periodic Overhauling of Track Machines

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Questions and Answers

What is the significance of tracking the total days lost due to machine breakdown?

It assesses the efficiency of the production schedule. (correct)

It monitors the performance of machine operators.

It helps in calculating total operational costs. (correct)

It indicates employee attendance.

Which of the following components is least likely to be associated with section-wise performance assessment?

General section

Lifting unit

Employee salary (correct)

Total days lost

What does the term 'repeated failures' refer to in the context of assembly performance?

Failures that are recorded only once.

Failures that happen multiple times for the same assembly. (correct)

Minor issues that do not affect overall performance.

Failures that occur after maintenance.

Which information is essential for calculating the impact of breakdowns in a production section?

Total time lost in block section Signup and view all the answers

How can the performance of an assembly be evaluated after 90 days of operation?

Through a fill of satisfaction levels for specific metrics. Signup and view all the answers

What is the primary focus of the study of failures in maintenance practices?

Finding remedial measures and troubleshooting Signup and view all the answers

What is the initial action that Zonal Railways must take concerning the POH programme?

Send a list of machines due for POH annually Signup and view all the answers

How does the CPOH Workshop finalize the POH programme?

By preparing a firm programme for the first year and a tentative one for the second year Signup and view all the answers

What is essential for the Zonal Railway to communicate to Dy.CE/TM (CPOH) regarding machine readiness?

A detailed report two months prior to arrival Signup and view all the answers

What documentation should Zonal Railways submit to the CPOH workshop?

A list of machines due for POH and requirements for overhauled tamping units Signup and view all the answers

What is a key responsibility of the CPOH after receiving the POH programme?

Starting the procurement process for necessary spares Signup and view all the answers

Which of the following is NOT part of the responsibilities outlined for the CPOH?

Evaluating the comfort of operators Signup and view all the answers

What role does the CPOH play in relation to track machines?

Acting as knowledge centers for track machines Signup and view all the answers

How many types of lathes are listed along with their sizes?

Three types of lathes Signup and view all the answers

What is the stroke length of the shaper machine?

0-300 mm stroke Signup and view all the answers

How many portable filters are listed for the POH capacity of 50 TMUs per annum?

4 Nos. Signup and view all the answers

Which of the following items does not have a specified number for the IOH shed/ZMD?

Electrical crimping machine Signup and view all the answers

What type of machine has two sets listed for the POH capacity of 50 TMUs per annum?

Accumulator nitrogen gas filling equipment Signup and view all the answers

Which machine listed has a size of 2000 X 500 mm for its table?

Horizontal boring machine Signup and view all the answers

Which equipment specifies having only one unit for its IOH shed/ZMD?

Induction type bearing removal unit Signup and view all the answers

What is the number of high-pressure cleaning chambers listed?

1 Set Signup and view all the answers

How many distinct models of rivet machines are mentioned?

Two models Signup and view all the answers

Which of the following machines has the largest number listed?

Portable filter Signup and view all the answers

What is the size of the inspection pit provided for each depot?

No specific size mentioned Signup and view all the answers

How many rooms for inspection, JFT and rejected items are to be provided for a depot?

4 rooms of size 8 m X 5 m Signup and view all the answers

Which of the following materials is mentioned in the construction of the depot?

Galvanised Aluminium Signup and view all the answers

What is the size of the open fenced space for stacking release spares in a depot with a POH capacity of 50 TMUs per annum?

30 m X 30 m Signup and view all the answers

What facilities are included in the Administrative block for officers?

Visitor's room and conference hall Signup and view all the answers

Which administrative block has a separate earmarked facility for lady staff?

GF Block Signup and view all the answers

What drainage arrangements are specified for the concrete aprons?

Proper drainage systems shall be provided Signup and view all the answers

How many rooms are designated for storage in the depot with a POH capacity of 24 TMUs per annum?

8 rooms of size 8 m X 10 m Signup and view all the answers

What is one feature of the roof structure in the depot?

Translucent sheets comprising 10-15% Signup and view all the answers

What feature is included for the stacking and keeping of scrap in the depot?

Open fenced space of 30 m X 30 m Signup and view all the answers

How many vehicles can the garage for POH capacity accommodate per annum at the location with the highest capacity?

5 vehicles Signup and view all the answers

What is the total length of the line for camping coaches at the POH capacity of 50 TMUs per annum?

250 m Signup and view all the answers

Which test bench is available at all three POH capacity locations?

Hydraulic test bench Signup and view all the answers

What is the capacity of the garage for the ZMD location?

2 vehicles Signup and view all the answers

Which of the following items is not included in the Satellite Depot?

Canteen Signup and view all the answers

How many ZF test benches are available at both the first and second locations of POH capacity?

1 Signup and view all the answers

What is the total number of test benches for tamping units at the POH capacity of 24 TMUs per annum?

2 Sets Signup and view all the answers

Which of the following sheds is listed as having only one unit across the different locations?

Cycle and Scooter shed Signup and view all the answers

Which test bench has the least quantity across all locations?

Test bench for PCBs Signup and view all the answers

At the POH capacity of 50 TMUs per annum, how many total test benches, including different types, are available?

12 Signup and view all the answers

Which of the following statements accurately describes the function of the Central Periodical Overhauling Workshop (CPOH)?

The CPOH is responsible for developing expertise and standardization in overhauling components. Signup and view all the answers

What is the maximum validity period for a refresher course certificate issued for training in ultrasonic examination?

5 years Signup and view all the answers

Which of the following types of workshops is specifically designated for periodical maintenance of track machines?

Central Periodical Overhauling Workshop (CPOH) Signup and view all the answers

Which engineering qualification is NOT explicitly mentioned as a prerequisite for training in ultrasonic examination?

M.Sc in Physics Signup and view all the answers

What is one of the functions that CPOH workshop performs for Zonal Railways after the POH?

Performance monitoring of overhauled items Signup and view all the answers

Which type of workshop is described as having mobile capabilities?

Mobile Workshop cum Transport Van Signup and view all the answers

Which qualification requires the candidate to have studied Physics at previous educational levels?

M.Sc in Chemistry Signup and view all the answers

Which of the following workshops would be utilized for immediate and mobile maintenance needs?

Mobile Workshop cum Transport Van Signup and view all the answers

What is the maximum system pressure range that needs to be calibrated for the parameter 'System Pressure'?

0-250 bar Signup and view all the answers

Which hydraulic parameter has a specific calibration requirement of 210 bar for both WST and UNI-2S masters?

Vibration Pressure Right Signup and view all the answers

Which listed item has a total of 300 sets allocated across different categories?

Appron, Helmet, goggles, mask & safety shoes Signup and view all the answers

What is the specified pressure setting for the Safety valve, which is important in hydraulic systems?

175 bar Signup and view all the answers

Which parameter category specifies a working range involving multiple accumulators with peak values of 140 bar and 315 bar?

Accumulators Pressure Signup and view all the answers

What is the total number of digital multimeters listed across all specified categories?

12 Nos. Signup and view all the answers

Which set of tools has the highest quantity listed for the mechanical tools category?

Mechanical tools, spanners Signup and view all the answers

What is the lifting capacity of the synchronized jacks mentioned in the tools list?

50 t Signup and view all the answers

In the category of EOT cranes, how many total 5 t cranes are specified?

4 Nos. Signup and view all the answers

How many sets of mechanized hydraulic arrangements are listed?

4 Sets Signup and view all the answers

How many sets of hose crimping machine units are indicated in the list?

1 No. Signup and view all the answers

Which equipment has the least quantity specified in the working tools section?

Nominated assembly tools for ZF Signup and view all the answers

What is the specified capacity of the mechanical screw jacks listed for lifting machines?

50 t Signup and view all the answers

Which of the following instruments is NOT indicated as part of the precision inspection set?

Hydraulic power pack Signup and view all the answers

How many sets of pneumatic tools for assembly/disassembly work are available?

4 Sets Signup and view all the answers

What is a requirement for the mobile van carrying fuel in relation to safety standards?

It must fulfill statutory safety standards. Signup and view all the answers

What type of vehicle is required for transporting spare parts and assemblies?

Vehicles with crane facilities for loading and unloading. Signup and view all the answers

Which communication facility is specifically mentioned for the machine in-charge?

Two walkie-talkie sets on the frequency used by operating staff. Signup and view all the answers

What type of connectivity is provided to all JEs/SSEs?

Voice and data connectivity through CUG mobile SIMs. Signup and view all the answers

What additional communication system is suggested for use between the work site and adjoining stations?

A walkie-talkie/VHF communication system. Signup and view all the answers

Which facility is NOT specified for the officers of Track Machines Organization?

Internet broadcasting facilities for remote locations. Signup and view all the answers

What is the purpose of the walkie-talkie sets for the machine in-charge?

To ensure smooth operation of the machinery. Signup and view all the answers

In what scenario might hiring vehicles be necessary for transporting spare parts?

If departmental vehicles are not available. Signup and view all the answers

What should be available for communication during the actual work in machines like BCM and TRT?

A head-mounted communication system covering one ear only. Signup and view all the answers

What may be considered for storage of HSD oil for daily operations?

Storage facilities at selected locations. Signup and view all the answers

What is the primary function of service groups created for field attention during breakdowns?

To provide specialized support in hydraulics, pneumatics, electronics, and electrics Signup and view all the answers

Which of the following activities does NOT relate directly to preventive maintenance practices?

Direct response to on-site emergencies Signup and view all the answers

In preparing the programmes for IOH and POH, what timeline must Zonal Railways adhere to?

Finalizing a firm plan for the current year and a tentative plan for the next Signup and view all the answers

What type of components does the infrastructure at the ZMD focus on housing?

Track machines and their essential spare parts Signup and view all the answers

Which of the following is a critical aspect of failure study in maintenance practices?

Developing trends from past breakdowns Signup and view all the answers

What is a significant result expected from the preparation of an inventory list for new machine models?

Assessment of changes against previous series for efficient maintenance Signup and view all the answers

What purpose does the advancement of procurement actions serve in the context of IOH and POH?

To ensure the availability of spare parts for upcoming maintenance Signup and view all the answers

Which type of facility is essential at the ZMD to facilitate machine repair and assembly?

Sheds and structures specifically designed for housing machines Signup and view all the answers

Which operational procedure is prioritized during the planning of IOH?

Appropriate advance preparation based on machine surveys Signup and view all the answers

What should the Zonal Railways do at the end of January regarding the IOH and POH programmes?

Submit their prepared plans for information and target setting Signup and view all the answers

Study Notes

Periodic Overhauling (POH) of Track Machines

POH is essential for ensuring the reliability and efficiency of track machines.
CPOH (Centralized Periodic Overhauling Workshop) plays a crucial role in POH planning and execution.
Zonal Railways are responsible for sending the list of machines requiring POH to CPOH workshops.

POH Planning

Zonal Railways submit a two-year POH program to CPOH workshops in December each year.
CPOH finalizes the program and submits it to Railway Board for approval by January 31st.
Railway Board approves the POH program and the distribution of tamping units for two years.
CPOH initiates procuring spares based on the approved program.

POH Workshop Infrastructure

CPOH Workshops are equipped with various facilities for POH, including:
- Galvanized aluminium/aluminium sheet sheds with thermal insulation and exhaust systems.
- Inspection pits with drainage systems.
- Rooms for inspection, Jig Fixture and Templates (JFT), and rejected items.
- Store wards for spare parts and equipment.
- Open fenced spaces for stacking release spares and scrap.
- Administrative blocks with offices, conference halls, and staff facilities.
- Two tracks for machine movements.

Essential Plant and Machinery

Test Benches:
- Tamping unit test bench with computer interface and data acquisition system.
- Hydraulic test bench with load testing facility and data acquisition system.
- ZF test bench with computer interface and data acquisition system.
- Test benches for PCBs, pendulums, transducers, sensors, alternators, and self-starters.
Machine Shop Equipment:
- Lathes, a shaper machine, tool grinder, horizontal boring machine, centralized compressor, portable filters, a vertical boring machine, wheel de-pressing and pressing machine, induction heater, bearing removal unit, electrical crimping machine, riveting machines, a hot air blower, a high-pressure cleaning chamber, accumulator nitrogen gas filling equipment.

Key Data Points for POH

Total days machine worked
Total days block taken
Total days lost due to breakdown of machine
Section-wise data:
- Total days lost due to breakdown for each assembly
- Total number of failures
- Total time lost in the particular section
- Number of repeated failures
- Performance of the assembly after 90 days of working.
Status of Section-wise Performance During POH: Evaluating the performance of each component of the machine.

Engineering Qualifications

Candidates must hold a 3-year Diploma in Mechanical, Civil, Electronics, Electrical, Metallurgical or Chemical Engineering from a recognized University or Institution.
Candidates with an M.Sc. in Chemistry are eligible if Physics was studied at ISC, Intermediate or 10+2 level.
A B.E/B.Tech. in Mechanical, Civil, Electronics, Electrical, Chemical, Metallurgical, I.T or Computer Science from a recognized University or Institution is required.
Initial course certificates are valid for 3 years and refresher course certificates are valid for 5 years.

Training Requirements

The Research Designs and Standards Organization provides training for supervisors in ultrasonic examination of axles and wheels.
Railways must nominate eligible staff for training.

Track Machine Workshops

Five types of workshops are established for repairs and maintenance of track machines:
- Central Periodical Overhauling Workshop (CPOH)
- Intermediate Overhauling Workshop (IOH)/Zonal Machine Depot (ZMD)
- Satellite Depot
- Mobile Workshop cum Transport Van
- Camp Coach Workshop

Central Periodical Overhauling Workshop (CPOH)

CPOH workshops are established considering the number of machines and geographical factors.
Functions of CPOH include:
- Periodic overhaul (POH) of machines.
- Overhauling of tamping units, transmission gearboxes, axle assembly and lifting, lining assembly.
- Post POH service to Zonal Railways and performance monitoring.
- Development of expertise, standardization, documentation and dissemination of knowledge.
- Study and development of component and sub-assembly interchangeability.
- Need-based overhauling or unit replacement of engines, tamping units, gear assembly, axle assembly and lifting, lining assembly.
- Field attention in case of breakdowns.
- Assistance to machine and satellite depot staff for heavy repairs and scheduled maintenance.
- Failure analysis, remedial measures, troubleshooting and maintenance practice development.
- Procurement of stores and equipment for operation and maintenance.
- Annual calibration of machine gauges.
- Preparation of inventory lists for new machine series/models.
- Development of indigenous substitutes and reliable competitive supply sources.

Zonal Machine Depot (ZMD)

ZDs are equipped with stores for spare parts and consumables, facilities for housing track machines, and areas for carrying out repairs, assembly and replacement of unit components.
ZMDs are provided with offices for SSE and track machine officers.
Typical infrastructural facilities at ZMDs include sheds, structures, plant and machinery, measuring and working tools, and other miscellaneous equipment.

Programme of IOH and POH

Zonal Railways prepare programs for IOH and POH of track machines.
Programs are finalized by end of January with firm plans for the first year and tentative plans for the second year.
Programs are sent to the Railway Board for information and consideration during target finalization.
Procurement action is planned for a period of two years based on the program.

Planning of IOH

Adequate planning is done after surveying the machines requiring overhaul.

Storage and Carriage Facilities for Fuel and Oil

Special road mobile units equipped with pumping arrangements are provided to carry and distribute fuel, lubricants and hydraulic oils.
Mobile fuel vans must meet statutory safety standards.
More than one unit may be required per satellite depot depending on the number of machines.
Storage facilities for HSD oil required for daily operations can be established at selected locations.
Involving oil companies on the lines of RCDs is a potential option.

Transportation of Spare Parts and Assemblies

Spare parts and assemblies are transported by road.
One or more road vehicles equipped with crane facilities for loading and unloading are provided at ZMDs and satellite depots.
Vehicle hiring is considered if departmental vehicles are not available.

Communication Facilities

JEs/SSEs receive voice and data connectivity via CUG mobile SIMs.
Walkie-talkie/VHF communication systems are used between work sites and adjacent stations.
Machine in-charge personnel carry two walkie-talkies compatible with operating staff frequencies.
Communication from mid-section to Engineering Control is utilized when available.
Head-mounted communication systems are provided for communication during work on machines such as BCM, SBCM, T-28, TRT and TLE.
Officers in the Track Machines Organization have access to STD and FAX facilities at ZMDs & SDs.
Each machine is equipped with a mini laptop and data card for uploading details into TMS.

Machine Requirements for Calibration

The text provides a detailed list of parameters to be calibrated on various machine models, along with the required master reference for each parameter.

Hydraulic System

The hydraulic system parameters listed include squeezing pressure, system pressure, vibration pressure (left & right), counter pressure for both small and big squeezing, accumulator pressure for various accumulator sizes, pressure setting of safety valve for system pressure, oil cooler motor pressure, high pressure setting, ZF oil pressure, charging pressure of variable pumps, work drive pressure, satellite bypass pressure, control pressure, travel drive pressure, main conveyor pressure, waste conveyor drive pressure, waste conveyor upper pressure, distributor drive pressure, cutting chain drive pressure, clutch pressure (front & rear), chain guide pressure (left & right), rail clamp pressure, chain tension pressure, cutter bar lifting pressure, cutter bar locking pressure, L/U up and down pressure, AC drive pressure, screen unit vibration pressure, screen tilting pressure, distributor conveyor in/out pressure, excavating conveyor pressure, hydraulic vertical load pressure, vibration pressure of vibrating unit, pre load pressure, broom drive pressure

Pneumatic System

The pneumatic system parameters are pneumatic system pressure, pneumatic intermediate pressure, break pressure, vertical preload pressure, satellite brake pressure

Electronic System

Electronic system parameters include cross level (by front, middle, and rear pendulum), height transducer value, super elevation value, general lift value, versine value (by lining transducer, measuring transducer, and versine potentiometer), slew value by slew potentiometer, tamping depth value, engine oil pressure gauge (NTA), engine temperature gauge (NTA), engine oil pressure gauge (KTA), engine temperature gauge (KTA), vibration frequency, engine RPM-1, engine RPM-2

Machine Models

The machine models listed are CSM, 09-3X, WST, UNI-2S, UNI-3S, DGS, BCM, and FRM
Detailed information is provided for each machine model and the specific parameters and ranges for each one.

Master Reference

The master reference for calibration is designated by symbols like PG, MM, T, and Tachometer, followed by a number indicating the type of master reference needed for each parameter.
The text also includes the range of pressure (bar) or temperature (degree C) to which each parameter needs to be calibrated.

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Description

This quiz covers the essential aspects of Periodic Overhauling (POH) for track machines, including planning, execution, and workshop infrastructure. Learn about the roles of CPOH workshops and the procedures involved in ensuring the reliability and efficiency of track machinery. Test your knowledge on the POH process and the responsibilities of the Zonal Railways.