Maintenance of Rolling Stock - General (ACTM-642-662 PDF)

CHAPTER II MAINTENANCE OF ROLLING STOCK – GENERAL III. 30200 Shed Organization 1. At the head of an electric loco (or EMU) shed will be Senior Divisional Electrical Engineer (Rolling Stock ) whose duties will be generally as defined in para 10108. He will be...

CHAPTER II MAINTENANCE OF ROLLING STOCK – GENERAL III. 30200 Shed Organization 1. At the head of an electric loco (or EMU) shed will be Senior Divisional Electrical Engineer (Rolling Stock ) whose duties will be generally as defined in para 10108. He will be assisted by one or more officers in lower ranks depending upon the work load. 2. The organization pattern in a loco shed will be generally as shown below : Sr. DEE(RS) DEE/AEE(RS)-I DEE/AEE(RS)-2 AEE/RS ACOS ACMT (Maintenance) (Maintenance) (General) (Stores (Laboratory) Depot) IOH, AOH & Heavy Quality Assurance General Repairs Inspections, Minor works. Schedules M2, M6 Light repairs Machine Shop Millwright E4, E5, E6 Testing and E7, E8, OUT-TURN M4,M7 S1, S2, S3 Technical PPO Matters Drawing Office Computer M1, M3, M5 Utilization E1, E2, E3 30201 Duties of Shop Superintendent/Chief Traction Foreman (Maintenance) He being supervisor in charge of the loco shed directly under the control of DEE/ AEE (RS), as the case may be, will be responsible for the maintenance of locos. His chief duties are: 1. To guide and instruct supervisors and men under him in the correct methods and schedules laid down for maintenance and repairs. 2. To keep a close watch on maintenance so as to reduce the unscheduled withdrawal of locos to the minimum and to watch the performance of equipment involved in frequent troubles. 3. To initiate appropriate steps for recommissioning locos out of service. 4. Execution of various approved modifications and to maintain locos and the loco shed in a clean condition. Indian Railways – AC Traction Manual – volume III 5. To keep a watch on the availability of stores for maintenance and modifications and to initiate appropriate steps for timely recoupment. 6. To ensure efficient maintenance of the shed plant and machinery and ancillary services. 7. To coordinate with TLC and TF(R) regarding withdrawal of locos for shed attention, POH and nomination of relief locos from shed. 8. To coordinate with the Training School regarding relief of staff for training and refresher courses. 9. He will be the stock holder of all equipments on locos, assemblies and sub-assemblies and unit exchange spares. 30202 Duties of Electrical Foreman (Planning and Progress Office) 1. To maintain liaison with the operating wing and ensure timely availability of locos from the shed. 2. To plan the scheduled and unscheduled repairs of locos to the shed as required, keeping in view the shed capacity and proper utilization of inspection, lifting and heavy repair berths. 3. To issue job cards and to coordinate the working of the sections so as to ensure timely turn- out of the locos after attention / repair. 4. To maintain necessary documents to enable scheduled attention to various locos and for revision of maintenance practices and instructions. 5. To keep a watch on tests and trials and performance of modified equipment and maintenance of requisite records in this connection. 6. To maintain the History Register, Equipment Cards, Modification Charts and other prescribed records. 7. To coordinate with the workshops regarding release of locos for POH and special shop repairs and to arrange for dispatch of requisite information and records to shops. 8. To maintain statistics of engine-kilometers, failure records etc. 9. To keep a record of wheel wear and to programme for tyre-turning. 10. Furnishing shed statistics to HQ office 30203 Duties of Section Supervisors Each of the section mentioned in 30200 will be under a supervisor of appropriate rank who will be directly responsible for the following: 1. He will scrutinize the job card for the loco received for inspection/unscheduled repairs, carefully study the work to be carried out and based on his personal inspection, list out additional items of work, if any, for approval as explained in para 30210. 2. He will allot the work to the staff under him with special instructions, if any. 3. He will ensure that the work is carried out within the time allotted and the loco released in time. 4. The supervisor will maintain a record of work done by staff with the purpose of taking corrective action in the event of reported malfunctioning of the equipment immediately after overhaul/repair. INDIAN RAILWAYS – AC TRACTION MANUAL – VOLUME III 5. He is responsible for drawing, distributing and recording of all stores required by his section, as well as any tools and testing instruments. 6. Before returning the job card in token of having completed the work, he will satisfy himself that all work has been done satisfactorily. To ensure this he will make frequent checks while the work is in progress. 7. He will ensure necessary co-ordination with other sections as well as with PPO. IV. 30204 Distribution of Work Load in the Shed Even though the classification of section in different Railways varies, the work load arrangement is typically as under: E1: a) To carry out preventive maintenance schedule inspections and overhauling schedules on battery charger, rectifier blocks. b) Trouble shooting and investigations of Unusual Occurrence Reports (UOR), withdrawal and failures of Electric Locos/EMUs. c) To oversee checking and complete testing of Elect. Locomotives nominated for VIP/Superfast trains and special trains. d) To oversee checking and complete testing of the nominated locos /EMUs by PPO. E1 section shall have a Quality Assurance Group consisting of competent supervisors and artisan staff who will carry out superchecking on nominated scheduled/unscheduled locos. E2: a) Test before and test after of all schedule inspection. b) Electrical inspection and repairs (minor) of parts noticed defective during inspections i.e. head lights, flasher lights, electrical equipments in BA panels, TFP, RPS, SL, Programme switches, MP, EMC, DBR, SMGR, CGR, tap changer, cables, cable sockets and cable connections. E3: a) To carry out scheduled inspection, unscheduled repairs, modifications, overhauling of traction motors. b) Connection and disconnection of traction motors before lifting and after lowering. c) To carry out scheduled inspection and unscheduled repairs, modifications and overhauling schedule of auxiliary motors. d) To disconnect and connect auxiliary motors while removing/refitting during overhauling scheduled and unscheduled repairs. E4: a) To carry out scheduled inspection, unscheduled repairs, modifications and overhauling schedule on all delicate and precision electrical equipment like relays, speedometers, ammeters, voltmeters and circuit breakers etc. b) To disconnect and connect speedometer connection /DJ connections during unscheduled repair. E5: Major repairs and overhauling of EP and EM contactors, smoothing reacator,RPS, flasher light, MP, TFP oil filtration, CGR,SMGR and tap changer (during IOH schedule / unscheduled visits) and modifications. E6: a) Removal and fitment of EMCs, EPCs, RPS, DBR during AOH schedule. INDIAN RAILWAYS – AC TRACTION MAN UAL – VOLUME III  b) Removal and fitment of SL,SMGR, Tap changer during IOH schedule. c) Overhauling of BA panel, head light, TK panel, SB panels, rotary switch board and switches during AOH/IOH schedule. d) Cleaning of cable junction boxes and cables during overhauling. e) Overhauling of SMGR and GR during AOH schedule. E7: Recabling work, partial or full E8: Electronic labs and PCBs etc. M1: a) Inspection and running repairs of mechanical parts, under frame, break gear, wheels and axles,buffing gear, body doors and windows, locks, side glasses, look out glasses etc. b) Special checks c) Carry out pre-summer, pre-winter and pre-monsoon checks. M2: AOH/IOH schedule work on i.e. centre pivot, side bearers, roof, buffing gear, cattle guard, rail guard, side glasses, look out glasses, doors, windows and locks. M3: Inspection, repairs and overhauling of pantograph. M4: a) To supervise the work of machine shop. b) To supervise proper functioning of Tool Room and its upkeep. c) To supervise and execute the re-profiling of wheel sets of electric locomotives on the pit wheel lathe and its preventive maintenance. M5: a) To carry out scheduled inspection and overhauling schedules on all pneumatic equipment except compressors and exhausters. b) Testing of all pneumatic equipments on test bench after overhauling. c) To carry out scheduled inspections,unschedule repairs, modifications and overhauling of compressors, exhausters and auxiliary compressors. d) Removal and fitment of compressors, exhausters and auxiliary compressors during overhauling, scheduled/unscheduled visits. M6: a) Mechanical disconnection and connection, lifting and lowering of locomotives. b) Heavy repairs and overhauling of bogies and other mechanical components like wheel sets, springs, axles boxes etc. c) Traction motor assembly and dis-assembly. M7: Remetalling of suspension bearings. PPO: a) Receipt and dispatch of locomotives/EMUs for their scheduled and unscheduled visits. b) Planning of scheduled and unscheduled repairs of locomotives / EMUs. INDIAN RAILWAYS – AC TRACTION MANUAL – VOLUME III  c) Monitoring the performance of development equipment. d) Maintenance of history books, history cards of equipment fitted. e) Keeping liaison with RSO regarding calling of locomotives/EMUs for scheduled/ unscheduled work. f) To keep record of wheel wear and to programme reprofiling. g) To scrutinize Electric Loco/EMUs log books on arrival of locomotives and issuing all job cards to the section supervisor for proper attention to the defects and to ensure that the work is done when the job cards are returned. S1: All works pertaining to procurement of stores and liaison with HQ for timely procurement of stores and upkeep of custody stores for not-stock items. S2: Specification updating section. S3: Tests and Trials sections. G: a) Electric and mechanical millwright sections. b) Maintenance of cranes and M&P itmes c) General upkeep of shed. d) Road Transport. Technical Section All technical correspondence of the shed i.e. outside and with in shed, updating and feeding of technical data in computer etc. Laboratory Physical and chemical testing of all items including ultrasonic testing of axles and shafts. Drawing office All drawing work, preparation of office estimates etc. Computer Section Operation of computer – collection of data and processing. V. 30205 Technical Section The chief responsibility will be : i) Keeping track of every failure of components. The failure should be analyzed in detail on the basis of which should emerge the analysis of the causes of failure, suggestions for improvements, modifications etc. ii) Documentation of all technical information. INDIAN RAILWAYS – AC TRACTION MANUAL – VOLUME III  iii) Keeping a watch that the maintenance instructions issued to the shed staff are up-to- date and ensuring that the instructions are explained to the concerned staff. VI. 30206 Specification Updating Section This section will be responsible with the drawing office, to update list of specifications and drawings against which different items are to be ordered and for issuing stocking advices to Stores Department. It should also keep records regarding consumable stores so as to pin-point any abnormal consumption for effective investigation. VII. 30207 Tests and Trials The observations regarding tests and trials should be carefully documented for the benefit of improving specifications or modifications to inspection schedules. The necessary documents should be centralized and kept in the PPO. VIII. 30208 Materials Management 1. This subject is dealt in detail in volume I. A few relevant items are being mentioned here. A. The various components – sub-assemblies and spare parts shall be purchased from the original/approved supplier of equipment. Railway may however make out a compendium of approved suppliers for each item/equipment, based on RDSO’s/production unit’s list. Any variation from the same shall only be permitted personally by Chief Electrical Engineer. B. For bringing in new suppliers in the compendium of approved suppliers, CEE may personally authorise use of untried and untested equipment for field trials. Special care is needed while approving any new make and type of brushes for traction motors. C. Storage of Rubber Components. Storage procedure in general for any type of rubber components are given below:- i) Rubber components should be kept away from direct sun light preferably in dark place. Direct sunlight causes much faster degradation of the rubber components. ii) They should be stored in a cool place as far as practicable, preferably below 300 C. iii) The humidity of the storage condition should not be such that condensation of moisture takes place on the surface of the material. iv) In the vicinity of these materials, any loose electrical connections should be avoided, as these cause production of ozone which adversely affects rubber. v) Rubber materials should be stored away from contact with certain materials particularly those containing copper and manganese which act as poisoning agents, aiding their fast degradation. vi) Under no circumstances rubber materials should be stressed during storage. The portions under stress undergo deformations with permanent set leading to degradation. The materials should be stacked in such a way so that any super-imposed stresses are substantially avoided. vii) Any contact with grease or oil should be avoided as these cause swelling, softening and deterioration of rubber materials. viii) French chalk should liberally be applied on the surface of rubber materials. Indian Railways – AC Traction Manual – volume III ix) Great care is to be exercised so that the material is used in the order of their receipt in the stores. The rubber material whether under storage or in use continues to deteriorate. The only difference is that under service condition, deterioration is much faster. Every moment of storing is at the cost of useful life and prolonged storage of the material may render it unserviceable due to progressive deterioration. IX. 30209 Demarcation of Responsibility between Sr.DEE (RS), DEE and AEEs The DEE / AEE (maintenance) will be responsible for day to day activities in the shed including unscheduled attentions and scheduled inspections. He will be particularly responsible for induction of any new type of stock in the shed and ensure that the maintenance schedule for such stock are finalized in the shortest possible time. The Sr.DEE will in addition concern himself with the broader aspects of work and forward planning such as watch-out for organizational shortcomings, indenting and progressing the procurement of forward delivery spares, maintaining a close watch on the functioning of the PPO and above all exercising vigilant technical control over unusual occurrences, recurring failures and unscheduled booking of locos to the shed and shall be in close liaison with Sr.DEE(OP). X. 30210 Job Cards For each loco/EMU received in a shed for scheduled or unscheduled attention, the PPO will issue a job card in proforma 2.01 to each section incorporating the following: a) The nature of inspection (IA, IB etc.) Refer to chapters III and IV. b) Additional items of work to be carried out on the loco/EMU by the section, based on booked defects, pre-inspection of the loco or planned modification. c) The time by which the loco/EMU is required to be released. Based on his own inspection, if the Section Chargeman finds that any items in addition to those mentioned by PPO are required to be attended to, he will get such work approved by TF(M) and get the additional items also entered in the job card by PPO. The job card will thus contain a complete record of all work done on a loco during its visit to the shed. When the work is completed, the Section Chargeman will sign the job card indicating the time of completion of the work and the names of the workers. The loco/EMU should be offered by the PPO for final inspection by E1only after job cards from all sections have received back duly signed by the respective Chargeman. XI. 30211 Shed Facilities Machinery and plant for Loco Sheds The list of machinery and plant recommended for a loco shed to cater for inspection, maintenance, overhaul and repairs including IOH of locomotives is indicated here under. List 1 – General Purpose Machine and Tools A. Machine Section 1. Lathe 250 mm swing, 1500mm between centres 1 2. Lathe 150 mm swing, 1000mm between centres 1 3. Portable tool post grinder for 12mm to 100mm dia wheel 1 4. Radial drilling machine 1 5. Universal milling machine 900mm x 300mm table with index 1 6. Shaping machine, 600mm stroke 1 7. Do-all band saw 1 Indian Railways – AC Traction Manual – volume III 8. Pillar drill (40mm hole in M.S.) 1 9. Power hacksaw to cut 150mm dia M.S. 1 10. Floor grinder 450mm dia wheels 1 11. Pipe threading machine 1 12. Pipe threading die sets 2 13. Pipe bending machine 1 14. Hand operated shearing machine 1 15. Marking table 1 Relay Room 1. Sensitive drill (20mm hole in M.S) 1 2. Watchmaker’s Lathe 1 Welding and White-metalling Section 1. Portable welding set 300A. dc. 1 2. Portable transformer welding plant 350A.ac. 1 3. Oxyacetylene welding and cutting set with 25 sets of cylinders for oxygen and acetylene 1 4. Eutectic weld deposit torch set 1 5. Smith’s hearth 1 6. Smith’s anvil and swage blocks. 2 7. Centrifugal white metalling plant (shop made) 1 8. Electric Furnace for melting bearing metal 1 Painting Section Spray guns portable compressor unit and reservoir with 2 spray guns 1 Tool Room 1. Portable electric tools : grinder, drills, Wrenches 3 2. Torque wrenches 5set Compressed Air Air compressor – complete with air drier and filter after-cooler, Reservoir, outlet valves 250cfm, 9kg/cm2 2 Vaccum cleaning, Water Pumps and Sanding. 1. Portable vaccum plant 2 2. Filter cleaning plant (shop made) 1 3. Pit dewatering portable electric pump 1 4. Booster pump for washing lines 2 5 sand drying and sieving plant 1 H. Other Electrical Equipment 1 Battery charger 2 2 Portable battery charger 1 3 Loading resistor for battery 1 4 Distilled water plant (Electrical ) 2 5 Oil centrifuging and filtering plant 1 INDIAN RAILWAY S – AC TRACTION MANUAL –VOLUME III 6. Pneumatic crimping tool for power cables 1set 7. Hand crimping tool for control cables 2set 8. Panto assembly fixture (shop made) 1set List 2 - Special Purpose Machines and Tools A. Bogie wheel sets. 1. Pit type wheel lathe 1 2. 50 tonne hydraulic press 1 3. 10 tonne hydraulic press 1 4. Horizontal boring machine 1000mm x 1000mm table 1 5. Hack `s burners 2 6. Bogie squaring jig 1set 7. Wheel profiling set (tool room ) 1 8. Grease guns and lubricating equipment (for each type of oil or grease ) 3set 9. Bearing extractor for transmission gears 1set 10. Lifting beam for locomotive body with stand 2 11. lifting tackle for bogie 1set 12. Spring testing equipment 1 13. Shock absorbers and snubbers testing rig 1 14. 25/30t hydraulic jacks for attending athermos bearing 5 B. Traction Motor and auxiliary machine Rewinding section 1. Pinion extractor 2 2. Pinion heating oil bath or induction heater 2 3. Auto transformer rectifier unit 100V,150Adc 1 4. Commutator turning lathe 1 5. Mica undercutting and chamfering machine for armature 1 6. Armature banding lathe 1 7. Dynamic balancing machine for armature 1 8. Vacuum impregnating plant 1 9. Baking oven 200 degree C with trolley 2 10. Baking oven 40-60 degree C with trolley 2 11. Baking dynamometer with test bed 1 12. Contator and relay coil winding machine 2 13. Brazing tongs with transformer 1 14. Brazing extractor 2set 15. Hand operated shearing machine for insulation 1 16. Traction motor assembly fixture, for each type of motor 1set 17. Grease guns 2set 18. Commutator electric soldering irons. 6 19. Surge tester 1 20. Dynamic balancing machine for auxiliaries 1 21. Bearing Extractor and inserter for traction motor and auxiliary machineries 1 22. TIG Welding kit 1 INDIAN RAILWAYS-AC TRACTION MANUAL-VOLUME III ( 46}  List 3- Testing and Measuring Instruments and Panels A Testing panels. 1. Test and calibration panel with meters for each type of relay. 1 2. Test and calibration panel with meters for speedometers 1 3. Test panel with meters for auxiliary machines 1 4. Loading dynamometer with test bed for auxiliaries 1 5. Test panel with meters for contactors, circuit breakers 1 6. Brake and pneumatic equipment test panel including air compressor 500 litre per min. 15kg/cm2 1 B. Testing and Measuring Instruments 1. 2500v megger 2 2. 500v megger 6 3 Universal multimeter 6 4. Portable voltmeter dc 3 5. Portable voltmeter ac 3 6. Portable ammeter ac 3 7. Portable ammeter ac 3 8. Current transformer set 20 to 2000 A 2set 9. Set of shunts for dc ammeter 75mV 2000A 2set 10. Millivoltmeters 0-75mV 2 11. Vacuum tube volt meter 1 12. Cathode Ray Oscilloscope 10cm display double beam 1 13. High voltage tester 0-75kV 1 14. High voltage tester 0-15kV 1 15. Oil tester 0-50kV 1 16. Current injection set 2000A, 3Vdc 1 17. Silicon diode tester 3 18. Ductors 2 19. Contact pyrometer (0-5000 C ) 3 20. Ultrasonic crack detector 1 21. Zyglo ultraviolet light crack detector 1 22. Brinell hardness tester 1 23. Shore hardness tester 1 24. Spring balance 0-1 kg 2 25. Recording ammeter 2 26. Recording voltmeter 2 27. Spring balance 0-3 kg 2 28. Spring balance 0-5 kg 2 29. Spring tester 1 30. Battery voltmeters 2 31. Anemometer 2 32. Manometer 2 33. Vibration meter 1 34. Capacitance and inductance bridge 1 35. Clip-on ammeters 0-5-10-25-10 250A 2 36. Dial gauges, vernier caliper, micrometers and feeder gauges. 2 37. Revolution counter 3 38. KWh meter with accessories for mounting on loco 2 39. Electric coil tester 1 40. Electric timer 1 41. Portable relay testing kit 1 INDIAN RAILWAYS –AC TRACTION MANUAL –VOLUME III (47) 42. Commutator profile recorder 1 43. Stop watch 2 44. Illumination meter 1 45. Wheat Stone bridge 1 46. Distilled water tester 1 47. Stroboscope / tachometer 1 48. Gear teeth micrometer 1 49. Tan-delta measuring instrument 1 50. Dissolved Gas Analyser 1 List 4 – Lifting, Handling and Transport equipment A Lifting and Handling Equipment. 1. 45 tonne electric overhead travelling crane with 6 2 no. tonne auxiliary hoist (50 tonne cranes for 132 tonne locomotives) 2. 25 tonne EOT crane with 6 tonne auxiliary hoist 1 3. 15 tonne EOT crane 1 4. 1.5 tonne monorail with electric hoist (in Stores Depot ) 2 5. Lifting tackles for transformer , traction motor armature, 1set ,loco underframe, roof sections, bogie, wheel set, loco,body etc. 6. 1 tonne monorail with chain pulley hoist 2 7. 2 tonne chain pulley hoist 3 8. capstan units 3 tonne 5 9. Tirfor 3 tonne 3 10. Hydraulic jack 50 tonne with traversing bases 1set 11. 50. Tonne screw jack with traversing bases 1set 12. 20 tonne high lift hydraulic jack with traversing bases 1set 13. Accommodation bogies B. Transport facilities 1. 2 tonne fork lift battery truck 1 2. 1 tonne pallet battery truck 1 3. 1 tonne material hand trolley platform type ( rubber tyres ) 3 4. 1 tonne hand pallet trolley 3 5. 7.5 tonne trolley on rail ( for traction motors ) 2 6. 5 tonne truck 1 7. jeep with trailer 1 8. Departmental wagon for armature 1 9. Departmental wagon suitably modified for transportation of wheels and bogies 2 C. Weighing Machine/ scales. 1. weighing machine 1 tonne (Stores Depot ) 1 2. weighing machine 50 kg ( stores Depot ) 1 INDIAN RAILWAYS –AC TRACTION MANUAL-VOLUME III (48)  List 5 - Work Benches, Lockers etc. 1. Workmen's tables, battery charging benches, armature trestles. 2. Bench Vices. 3. Individual fitters tools. 4. Locks and keys for workmen. 5. Steel almirahs and stores racks. 6. Steel tables and chairs cardex boards, filing cabinets, index cards cabinets, typewriter, calculating machines for PPO's office 7. Tables chairs for offices and supervisors, almirahs, filing racks, cabinets, typewriters, duplicator, drawing office, and Ferro printing equipment. 8. Time office equipment, time clock, ticket filing racks, tables and chairs. 9. PCB testing kit. 30212 Modification of Designs for Rolling Stock Railways should not adopt any new design or modify the existing approved designs except for trials, without the prior approval of RDSO. Procedure for Initiating and Progressing Modifications 1. One shed which has the bulk of the holdings of a particular class of loco / EMU will be nominated by the RDSO, in consultation with the Railway, as the parent shed for that class of loco /EMU. 2. Each Railway will continue to tackle operating and maintenance problems as hitherto, but will also furnish complete particulars of all problems and failures on each class of loco /EMU to the corresponding parent shed and RDSO together with the modifications evolved by it and further suggestions, if any. 3. The nominated parent shed will then collate all the information in regard to each type of failure, study the merits of the different improvements suggested from all angles and submit recommendations to the CEE of the Railways, giving. full particulars of the most satisfactory improvements / modifications after they have been actually tried out in service and found feasible. When any defect is found to be intractable and expert investigation is necessary, a comprehensive note on the subject should be prepared and submitted by the parent shed to the Headquarters Office. CEE will arrange to forward the considered recommendations to RDSO. 4. The recommendations received from the parent Railway will be subjected to a further scrutiny and analysis by the different wings of the RDSO after which final instructions regarding the standard approved method of modification / improvement will be issued to all concerned, giving an identification serial number to each with full details and drawings required for carrying it out. 5. On receipt of the instructions from RDSO, each user Railway will arrange to carry out the modifications on priority on locomotives / EMUs until the work is completed in all locomotives/ EMUs. Progress of implementation of the modifications will be regularly sent to CEEs office by each shed and CEEs office in turn will send a quarterly report of progress to RDSO. 30213 Records and Register to be Maintained in LOCO / EMU Sheds Particulars of some of the basic records to be maintained by sheds are given below: 1 History Book - For each electric locomotive / motor coach, a History Book should be maintained in the loco / EMU shed by the Planning and Progress Office, (PPO). The History Book should have separate pages allotted for recording the items listed below in the proforma shown against each. INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill a) Pre-commissioning details: i) Contract or order number against which received. ii) Date of despatch/shipment. iii) Date of receipt by the Railway. iv) Date put into service. v) Particulars of tests and trials carried out and reference to reports on these. vi) Particulars and serial number of major equipment initially provided. vii) Particulars of any major defects rectified or modifications carried out prior to commissioning. b) Defects and failures during the Guarantee period: ------------------------------------------------------------------------------------------------------------------------------------- Sl. Date Nature of Action taken Reference to reports No. Defect to rectify sent to Manufacturers/ Production Unit/RDSO etc. ------------------------------------------------------------------------------------------------------------------------------------- c) Statistical failures ------------------------------------------------------------------------------------------------------------------------------------- Sl. Date Brief details Repercussions Action Reference No. Of failure on traffic taken to detailed reports. ------------------------------------------------------------------------------------------------------------------------------------- d) Non-statistical failures: The same proforma should be followed as for (c). e) Progressive record of kilometres earned: ------------------------------------------------------------------------------------------------------------------------------------- Month and year Kilometres earned Cumulative Remarks during the month kilometers earned upto end of month ------------------------------------------------------------------------------------------------------------------------------------- f) Availability for traffic ------------------------------------------------------------------------------------------------------------------------------------- Month and year No. of hours Percentage Remarks available for traffic. availability ------------------------------------------------------------------------------------------------------------------------------------- g) Modifications (Electrical): ------------------------------------------------------------------------------------------------------------------------------------- Sl. Description of modification Authority Date of completion on No. This loco/motor coach. ------------------------------------------------------------------------------------------------------------------------------------- h) Modifications (Mechanical): This should be as maintained in the same proforma as for (g). i) Inspections, Overhauls and Unscheduled Repairs. ------------------------------------------------------------------------------------------------------------------------------------- Schedule Time in Time out Particulars of special work Carried out, if any ------------------------------------------------------------------------------------------------------------------------------------- j) Changes in Main Equipments: PPO should record particulars of replacement of complete units of main equipment such as Traction Motors, Transformer, Rectifier, Pantograph etc., together with serial numbers of the original and substituted items and reasons for replacement. INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill  k) Record of mechanical clearances with bearing on safety. This History Book should be sent along with the loco/EMU to the workshop when the loco/EMU is booked for POH for heavy repairs and should be received back with the loco/ EMU. The workshop should enter details of work done and modifications, if any carried out. 2. Equipment Cards: In the case of major items such as traction motors, transformers, rectifiers, circuit breakers, pantographs, tap-changers, auxiliary machines, bogies, wheels, etc. “Equipment Card” should be maintained in the shed by the PPO so as to have for ready reference the History of the equipment. Individual Cards should be maintained for each unit of major equipment and the individual cards may be stored grouping them either equipment wise or loco-wise as convenient. The equipment cards should contain details as shown below: EQUIPMENT CARD NO. ……………. Description of Equipment: Serial No. Date of commissioning : Loco/Motor Coach No. in which initially installed EQUIPMENT MOVEMENTS _______________________________________________________________________________ Serial No. of Loco / Emu Date In Out Reasons for movement _______________________________________________________________________________ HISTORY OF OVERHAULS _______________________________________________________________________________ Date removed for Date overhaul Particulars of work Overhaul completed _______________________________________________________________________________ HISTORY OF SPECIAL REPAIRS _______________________________________________________________________________ Date removed for Date repairs Nature of repairs Repairs completed _______________________________________________________________________________ 30214 Unusual Occurrence Reports A report indicating failure, withdrawal and any other technical abnormality in locomotive /EMU observed on line is called Unusual Occurrence Report (UOR). This should be made in each case recording in full detail as to what has actually happened and what steps should be taken in future to avoid recurrence. While suitable proforma may be laid down by each Railway to suite local requirements, the UORs should basically contain the following details: i) Report of Drivers/Motorman detailing all his observations, together with remarks of TF (R) and Officers incharge of operation. ii) Observations made by Maintenance Organization i.e. Technical Investigation section, Maintenance Foreman and AEE/DEE(RS). A sample proforma is appened (Proforma 2.02). UORs should be serially numbered for each calendar year to identify the homing shed, class of loco and serial number of the occurrence for the class of loco/EMU during the year e.g. TATA/WAG4/3/90. A copy of all UORs should be forwarded to CEE’s office periodically. INDIAN RAILWAYS-AC TRACTION RAILWAYS-VOLUME-III 30215 Periodical Review Information Each homing shed should maintain requisite records and compile the following statistical information for each month. While the report on availability and reliability of the locomotive should be submitted to CEE every month, the report on the cost of repairs and maintenance should be submitted quarterly. 1 Availability and Reliability Locomotives 1. Average authorized stock (on allotment basis) 2. Average total number on line (on allotment basis) 3. Average number under or awaiting repairs (on allotment basis) 4. Average number effective (fit for use) (on allotment basis) 5. Actual number in good repair stored (on allotment basis) 5a. Average number available for use (on allotment basis) 6. Average number in use 7. Average number of engines on the line for operation 8 Percentage of total engine hours spent 9. Engine km per day per engine in use on individual services 10. Engine km per day per engine on line on individual services 11. Engine km per day per engine in use on all services 12. Engine km per day per engine in use on line (on allotment basis) 13. Engine failure EMUs 1. Average authorized stock (on allotment basis) 2. Average total number on line (on allotment basis) 3. Average number under or awaiting, repairs (on allotment basis) 4. Average number effective (fit for use) (on allotment basis) 5. Actual number in good repair stored (on allotment basis) 5a. Average number available for use (on allotment basis) 6. Average number in use 7. Train km, passenger 8. Hours 9. Vehicle km (in units) 10. Train Usage 11. Vehicle used 12. Motor coach failures 13. Gross tonne km 14. Power used II Cost of Repairs and Maintenance 1. Engine km 2. Cost of repairs and maintenance per Engine km 3. Cost of repairs and maintenance per EMU stock (in units) 30216 Daily Loco/EMU Position 1. The Daily Loco/EMU position at 00.00 Hr, will be put up to CEE next morning. Over the years various railways have evolved their own proforma depending upon the local operating conditions. 2. The proforma as used on SE Railway indicating the Daily Loco position is enclosed (2.03). 3. The proforma as used by Eastern Railway indicating the EMU position is also enclosed (2.04). 4. Railway may evolve their own proforma based on these proformae. INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME 111  Job Card Electric Traction Rolling Stock Proforma 2.01 _______________________________________________________________________________ Job Homing Locomotive Location Head of Signature Working Date Date Card Shed No. of Loco Allocation of P.P.O. Team No. of of No. Foreman/ELC issue Receipt _______________________________________________________________________________ Nature of work to be done _______________________________________________________________________________ Particulars of work _______________________________________________________________________________ Details of Approxi mate materials used Expenditure _______________________________________________________________________________ Name of Worker ……………………… ………………………………………… ………………………………………… Signature of Chargeman Signature of Elect. Foreman Signature of Worker…………………… INDIAN RAILWAYS – AC TRACTION MANUAL – VOLUME III  PROFORMA 2.02 UOR NO................................................RAILWAY UNUSUAL OCCURRENCE REPORT FOR ELECTRIC LOCOS/EMUs Date.............. ------------------------------------------------------------------------------------------------------------------------------------- A. Driver's Report 1. Loco / Motor coach No. 2. Train No. and Time 3. Place of occurrence 4. Train Load 5. Catenary Voltage 6. Speed of train 7. Gradient at the place of occurrence 8. Weather conditions 9. Brief Description of occurrence B. Observations of ‘Operating Section' C. Observations of Maintenance Staff / Technical Investigation Section. D. History of Locomotive / Motor coach Involved 1. Last inspection date: 2. Commissioning / IOH date: 3. Any special repair carried out on this loco / EMU: 4. Kilometers earned after last IOH: E. Remarks of Sr. DEE / DEE (RS) 1. Findings regarding causes of failure or damage: 2. Responsibility of staff: 3. Recommendations for modifications or improvement to equipment or maintenance schedule or operating instructions: 4. Action taken for rectification:.......................... Sr.DEE / DEE (RS) INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill  PROFORMA 2.04 DAILY POSITION OF EMU COACHES DATE Availability HWH SDAH Punctuality HWH SDAH i) No. of units in service i) Overall ii) No. of units under repair ii) Progressive iii) No. of M/Cs sent to KPA iv) No. of T/Cs sent to KPA v) % ineffective M/C vi) % ineffective T/C vii) No. of M/C's with TM isolation & reasons. CTLC/TLC's Signature INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill