CnW Maintenance Manual - Infrastructural Facilities PDF

Chapter 11 Infrastructural facilities for freight yard, sick line and ROH depots: Page 1 of 15 CHAPTER – 11 INFRASTRUCTURE FACILITIES (For Freight yard, Sick line and ROH Depots) 1101 Introduction...

Chapter 11 Infrastructural facilities for freight yard, sick line and ROH depots: Page 1 of 15 CHAPTER – 11 INFRASTRUCTURE FACILITIES (For Freight yard, Sick line and ROH Depots) 1101 Introduction: To achieve best performance of freight stock it is necessary that these stocks are maintained properly. The maintenance pattern and practices to be followed have been described in the previous chapters of this manual. However, despite of best practices and trained manpower, proper maintenance, availability and reliability of assets cannot be achieved if adequate infrastructure is not available. Accordingly, the Railway Board has laid great stress on review and improving availability of required infrastructural facilities for maintenance and vide their letter no. ERB – I/ 2006/ 26/ 46 dated 14.12.06 nominated an ED’s committee for rationalization of train examination points, sick lines and ROH depots. The criteria for categorization of examination/repair facilities recommended by the ED’s committee are as under (Ref: Bd’s letter no. 96/ M(N)/ 204/ Vol -I / II dated 09.03.04, 02.11.04 and 05.08.04) A. Categorization of Examination / Repair facilities I. Intensive Examination Points Category Criteria for Categorization (i) Having pucca pathways on more than 50% of the lines nominated for examination. A (ii) Sufficient illumination facilites 150 lux. (iii) Sufficient material handling facilities. (iv)Sufficient welding facilities. (i) Having pucca pathways on more than 50% of the lines nominated for B examination. (ii) Sufficient illumination facilities. (iii) Sufficient material handling facilities. (i) Having pucca pathways on more than 50% of the lines nominated for C examination. (ii) Sufficient illumination facilities. D (i) Having pucca pathways on more than 50% of the lines nominated for examination. E No pucca pathway but some other facilities are available F No facilities available. II. ROH Depots Category Criteria for Categorization A Where all the infrastructural facilities are adequate. B Where all the infrastructural facilities are available but some not adequate to match target out turn C Where some vital infrastructural facilities like EOT crane/wheel turning lathe etc. are not available, other facilities are adequate. D Where facilities are grossly inadequate or non-existent. WAGON MAINTENANCE MANUAL Chapter 11 Infrastructural facilities for freight yard, sick line and ROH depots: Page 2 of 15 III. Sicklines Category Criteria for Categorization A (i)Berthing capacity under covered shed (ii) Heavy duty concrete flooring in working area. (iii) Availability of welding facility. (iv) Availability of Compressor/ Exhauster. (v) Availability of EOT crane B (i) Berthing capacity under covered shed. (ii) Heavy duty concrete flooring in working area. (iii) Availability of welding facility. (iv) Availability of Compressor/ Exhauster. (v) Synchronized whiting jacks. C (i) Berthing capacity under covered shed. (ii) Heavy duty concrete flooring in working area. (iii) Availability of welding facility. (iv) Hydraulic Jacks for lifting D (i) Berthing capacity under covered shed. (ii) Heavy duty concrete flooring in working area. E Berthing capacity under covered shed. F Without any Berthing capacity under covered shed. The details of infrastructural facilities required for examination yards, sicklines and ROH depots are described in subsequent paragraphs. 1102. INFRASTRUCTURE & FACILITIES REQUIRED IN THE YARD i. Centre to centre distance between tracks for nominated lines for conducting intensive examination should be minimum 7.5 meters. ii. Concrete pathways, material handling equipment, multi utility vehicle to facilitate movement of man and material smoothly from one end to other end. iii. Proper illumination, specially covering bogies and brake gear locations so that the wagons needing attention can be easily detected. iv. Welding grid on the entire length of train of nominated line with proper earthing arrangement so that welding can be carried out without marking the wagon sick. v. Enough outlets for tapping air pressure for testing of the stock. vi. Duty room for Section Engineer/Junior Engineer (C&W), staff room, air compressor room, store room for stocking material, tool room, welding machine room, battery charging room etc. vii. VHF sets / CUG phones for close monitoring and communication between supervisors, staff and Sr. Section Engineer (In-charge). viii. Portable LED type inspection lamps. A. MACHINERY & PLANT ITEMS The following machinery and plant are essential for train examination during yard maintenance: Diesel and Electrically driven Compressor Welding plants Wagon /Rake Test rig WAGON MAINTENANCE MANUAL Chapter 11 Infrastructural facilities for freight yard, sick line and ROH depots: Page 3 of 15 Hydraulic jacks of various capacities. Lister truck for carrying material such as brake blocks etc. DG set (Cap. 200 kva min.) Multi utility vehicle for transportation of Men, Materials and Tools from one end of rake to other. Gas/ Plasma cutting set. B. TOOLS Fitters should have the following tools. Tool Bag Hammer Chisel Punch (Flat & Round End) LED head lamp Spanners of various sizes Pipe wrench Wheel tyre defect gauge Measuring foot rule Measuring tape Non contact hot axle detector Cord for measuring spring camber Gauge for measuring “A” dimension Test plate “GO /NO GO” gauges To be made available in Section Engineer/Junior Engineer (C&W) office All types of jacks Banner flag/Tail lamp CBC height gauge Air pressure gauge Chisel with wire handle Punch with wire handle Sledge hammer Scale – Steel rule 6” Measuring tape – 3 m Allen key (full set) Circlip plier (internal & external 19-60 mm) Hacksaw with blade 12” Set of non sparking tools (for yard handling tank wagon) LED head lamp Helmet Ladder with platform 10 ft. height WAGON MAINTENANCE MANUAL Chapter 11 Infrastructural facilities for freight yard, sick line and ROH depots: Page 4 of 15 1103 INFRASTRUCTURAL FACILITIES FOR FREIGHT EXAMINATION YARD WITH WORLD CLASS FACILITIES FOR DETECHMENT FREE YARD (IF PROPOSED). (Ref.: CAMTECH’s Report No.CAMTECH/2007/M/W/Infra/1.0 Jan- 2008) i) The yard handling 5 to 10 rakes per day shall have two examination lines of 750 m each to facilitate creation of gap, one line for keeping sick wagons and one line for keeping fit wagons released from sickline. All the four lines should be under covered shed to facilitate all weather working. ii) The complete area of examination yard shall be provided with abrasion resistance granolithic concrete flooring and ballast free embedded track to ease movement of vehicles and material handling equipments. iii) Centre distance between the examination, sick and fit line shall be 7.5 m to ensure free movement of material handling equipments and minor attention. iv) No OHE wiring over the examination lines/Sick yard line /fit wagon line which shall be dealt with EOT crane. v) Top wiring at both the ends of the train examination line for dropping the rake and waiting for crew/loco after release. vi) TXR shall be provided with Industrial type Personal Digital Assistant (PDA) having pre-fed check sheets for recalling defects and examination data. vii) A dedicated engine for placement of rakes in examination line if the rake is received with electric locomotive. viii) A rail cum road shunting vehicle with capacity to haul 30 empty wagons shall be used for creating gaps between wagons. The vehicle shall also be provided with compressor and rake test rig for air brake testing of formations. ix) For yards handling upto 10 rakes per day, 7 EOT cranes of 30 tonnes lifting capacity, 30 mtrs. Span and 650 mtrs.travelling shall be provided. Each wagon shall be lifted with the help of EOT cranes by using specially designed slings for lifting from axle box. x) Major Sickline with all Infrastructural facilities would remain attached and adjacent to freight examination yard. xi) To expedite repairs in-situ, adequate number of material handling vehicles and multi utility vehicles shall be provided. xii) The covered shed shall be provided with alternate rows of metal halide lamps and set of T-5 tube light fittings. The illumination around covered shed should be provided by high intensity tower lights. xiii) Electric panel with junction box at a distance of 30 m shall be provided in between sick yard line and examination line. xiv) Effective communication system preferably CUG mobile phones or walkie talkie sets shall be provided across teams. xv) A comprehensive contract for day to day upkeep of the yard is recommended for major and mega yards. This contract should cover items like scrap lifting and bush cutting in the periphery of the yard. xvi) A running contract for petty repairs pertaining to shed and floor of the yard including civil and electrical engineering works is also recommended. This contract will be monitored by field officer of Mechanical Department. xvii) A running contract for maintenance of all major M&P such as EOT cranes, compressor, vehicles, welding sets, hydraulic jacks is also recommended. WAGON MAINTENANCE MANUAL Chapter 11 Infrastructural facilities for freight yard, sick line and ROH depots: Page 5 of 15 1104. INFRASTRUCTURAL FACILITIES IN AIR BRAKE ROH DEPOTS Air brake depots have been classified based on the target capacity for ROH outturn/month as follows: Category Targeted capacity for ROH (Average/month) Super Depots Above 500 Mega Depots 250 to 500 Major Depots 125 to 250 Minor Depots Upto 125 A. RECOMMENDED LAYOUT Analysis of sick marking of existing ROH depots on IR reveals that on an average each air brake wagon visits the depot thrice in 18 months, once for schedule ROH and twice for out of course repairs requiring lifting. Therefore, an air brake depot meant for undertaking 250 ROHs/month needs to tackle another 500 wagons/month out-of-course repairs requiring lifting. Thus the layout should be spacious enough to release about 25-30 wagons/day. The ROH schedule should be completed within 24 hours including placement and withdrawal time. Thus, if the depot has to undertake 250 ROHs/month the berthing capacity for ROH wagons on trestles should be 12 taking 20% margin for heavy repairs. Considering a mixed ROH outturn and the working length for BOXN as 15m & BCN/BTPN as 20 m, the length of the ROH depot works out as 100 m. Casnub bogies require extensive repairs of bogie components. These bogies need to be tackled on bogie manipulators to ensure down hand welding. All wearing surfaces need to be built up to original (new) sizes. Further, all modifications issued by RDSO need to be implemented to ensure adequate safety. The bogie section is required to supply 20 bogies/day for undertaking 250 ROHs/month apart from repairing bogies required for out-of -course repairs. For this purpose, adequate work stations need to be set in a cranage area of about 2500 sq.m. (including wheel lathe area). Recommended layout of bogie and body repair section for a Major depot undertaking 250 ROHs per month along with sick line work of out-of-course repairs is given on next page: WAGON MAINTENANCE MANUAL Chapter 11 Infrastructural facilities for freight yard, sick line and ROH depots: Page 6 of 15 Body repair section EOT 15t /5t EOT 15t/5t 25m EOT 10t/3t EOT 10t/3t 25m Wheel lathe Bogie repair section 100 m Further details of the model layout and its end view are given in the attached Fig. II-A. The above layout has to be supplemented with facilities for Stores, machine shop, smithy shop, air brake equipment overhauling sections, model room, compressor room, canteen, hostel, etc. which will largely depend on the existing layout. Covered area under cranes i.e. cranage area for a fixed ROH outturn is a function of placement/withdrawal and number of working shifts. The recommended cranage area for depots undertaking 250 to 500 ROHs per month is given below: 1. For ROH depots with Sick-line attention 250 5000 sq. m including wheel lathe shed. 300 ROHs/month + sick line 5600 sq. m. 350 repairs with double shift. 6200 sq. m. 400 6800 sq. m. 450 7400 sq. m. 500 8000 sq. m. 2. For ROH depots WITHOUT Sick-line attention Depots undertaking only ROH workload and no out-of-course repairs can manage the outturn of 250 ROHs/month in about 3000 sq. m. cranage area working in double shifts. WAGON MAINTENANCE MANUAL  Chapter 11 Infrastructural facilities for freight yard, sick line and ROH depots: Page 7 of 15 B. MODEL LAYOUT FOR UNDERTAKING 250 ROHs/ MONTH BOX WHEEL LATHE BCN BOXN 100M BOGIE REPAIR SECTION BCN BOXN TRACKS Lean-to-roof Running tracks for DVS(Sick) wagons Lean-to-roof Lean-to-roof 10t/3t EOT (2 Nos.) 15t/5t EOT (2 Nos.) 1.6 3.2 2 3.2 5 3.2 2 3.2 1.6 25 M 25 M Fig. II-A WAGON MAINTENANCE MANUAL Chapter 11 Infrastructural facilities for freight yard, sick line and ROH depots: Page 8 of 15 C. REQUIREMENT OF MACHINERY AND PLANTS M&P requirement is closely linked with the Depot layout and the system of working. Certain M&Ps are directly related to outturn of depot (e.g. welding machines) but certain M&Ps are related to depot layout, especially material handling equipment. Various repair centres/sections in a depot are as follows: 1. Body shop 2. Bogie shop 3. Air brake equipment 4. Wheel reconditioning 5. Machine shop & material reclamation 6. Stores 7. Black smithy shop 8. Training equipment 9. Canteen & Staff amenities 10. Management information system 11. Office equipment 12. CMT laboratory 13. Miscellaneous. Recommended list of M&P for a unit depot i.e. handling 250 ROH per month is given below. For a depot handling more than 250 ROH per month, the requirement has to be scaled up depending on depot layout and facilities created. Requirement of M&P for each section is given below: 1. Body section Sr. No. M&P Quantity 1 EOT cranes 15t/5t 2 Nos. 2 Welding machines 4 Nos. 3 Portable hydraulic rivetter 1 Nos. 4 Trestles 12 sets 5 Winches As per layout 6 Portable Grit Blasting Machine 1 No. 7 Lock bolting machine 02 Nos. 8. MIG welding sets 02 Nos. 9. Plasma /Gas cutting 04 Nos. 2. Bogie section 1 EOT crane 10t / 3t 2 Nos. 2 Welding machines 6 Nos. 3 Portable hydraulic riveter 1 Nos. 4 Stores bin 50 Nos. 5 Portable electric grinders 3 Nos. 6 Jib crane 2.5t 10 Nos. 7 Fixture for rivetting spring plank 2 Nos. 8 Work station for bogie repair 10 Nos. 9 Turn table for wheel sets As per layout. 10 Road crane 10t capacity 1 No. 11 Bogie manipulators 3 Nos. 12 Roller bearing diagnostic equipment 2 Nos. 13 Magnetic flaw detector 2 Nos. 14 CO2 welding machine 2 Nos. WAGON MAINTENANCE MANUAL Chapter 11 Infrastructural facilities for freight yard, sick line and ROH depots: Page 9 of 15 3. Air brake equipment 1 Elec. Stationery screw air compressor completes 1 No. with air receiver 15 m 3/min (This is for depot only. Additional compressors will be required for yard). 2 Portable diesel compressor 1 No. 3 Single Wagon test rig 2 Nos. 4 DV test stand 1 No. 5 Hydraulic pipe bending machine 1 No. 6 Air conditioners with voltage stabilizer 2 Nos. 7 Torque wrench with various sizes of sockets less 4 set. than 1 inch. 8 Ultrasonic cleaning table for DV components 1 Nos. 4. Wheel Reconditioning Equipment 1 Surface wheel lathe with Servo controlled voltage 1 No. stabilizer 2 Pneumatic torque wrench with sockets 1” to 2” 4 sets 3 Pressure grease drum with guns 15t capacity. 2 Nos. 4 Ultrasonic flaw detector 2 Nos. 5 Bearing marking gadget 1 set 6 Mono-rail for handling swarf (detail plan will 1 set depend on layout) 7 Bins for storing bearings As per requirement 8 Fork lifter 2.5t 1 No. 9 P.C. Terminal 1 No. 10 Wheel diameter measuring gauge 2 Nos. 5. Machine shop & material reclamation 1 Heavy duty shaping machine 1 No. 2 Jib crane 2.5t 1 No. 3 Centre lathe 12 ½” cap. 1 No. 4 Redial drilling machine 1 No. 5 Centre lathe 6” cap 1 No. 6 Bench drilling machine 1 No. 7 Heavy duty pedestal grinder double ended 1 No. 8 Shearing machine 6 mm 1 No. 6. Stores 1 Truck 10t capacity 1 No. 2 Tractor with hydraulic lifting machine and 3 1 No. trolleys (trailers) 3 Fork lift 2t 2 No. 4 Platform truck 2t 2 Nos. 5 Battery charger 2 No. 6 Weighing machine 500 kg 1 No. 7 Light store vehicle 1 No. 8 Hand trolleys with rubber wheels 10 Nos. 9 Storage racks As per layout WAGON MAINTENANCE MANUAL Chapter 11 Infrastructural facilities for freight yard, sick line and ROH depots: Page 10 of 15 10 Computer terminal with printer 1 No. 11 Furniture As per layout 7. Training equipment 1 Cut models of DV, SAB, Angle cock. 1 set (each) 2 Television /DVD player 1 set 3 Furniture As per reqt. 4 Hostel along with kitchen equipment As per requirement 5 LCD projector 1 No. 6 PC 02 Nos. 8. Canteen & staff amenities 1 Water cooler 3 Nos. 2 Stainless steel tables & chairs As per reqt. 3 Kitchen equipment, cooking gas, utensils As per reqt. 4 Fitter’s lockers As per reqt. 9. Office Equipment 1 PC terminal As per reqt. 2 Printer As per reqt. 3 Furniture As per reqt. 4 Air conditioner & computer room. As per reqt. 5 Intercom 10 lines 1 No. 6 Fax with P&T line 1 No. 7 First aid equipment 4 set 8 Photocopier 1 No. 9 V.H.F. / CUG phones As per reqt. 10. Miscellaneous 1 Gas cutting equipment 4 Nos. 2 Hydraulic jacks As per reqt. 3 SAB test bench 1 No. 4 CBC and draft gear replacement equipment 2 sets 5 DG set 350/500 KVA 1 No. 6 Electric and pneumatic tools As per reqt. 7 Rivetting equipment As per reqt. 7 Fitter’s hand tools. As per reqt. 8 Gauges & instruments. As per reqt. 9 Wheel flat detector system (*) As per reqt. (*) To be installed in depots/yards as per instructions of Railway Board. Note: Where power failures are rampant, a Diesel Generating Set to run the wheel lathe and cranes may also be planned. WAGON MAINTENANCE MANUAL Chapter 11 Infrastructural facilities for freight yard, sick line and ROH depots: Page 11 of 15 1105. FACILITIES REQUIRED FOR MAINTENANCE OF STAINLESS STEEL WAGONS: Facilities ( M&Ps and consumables) for maintenance of stainless steel wagons in freight yard, sick line and ROH depot: Freight Yard Sick line ROH Depot S.No. Item/description (maintaining (5 wagons (ROH/month 200 3 rakes/ day) /day) wagons) MIG/MAG Welding 02 Nos. 02 Nos. 03 Nos. 1. Sets (400 Amp.) DC Arc Welding 02 Nos. 02 Nos. 03 Nos. 2. Rectifier (600 Amp.) Portable Air Plasma 02 Nos. 02 Nos. 03 Nos. 3. cutting machine (max. capacity 16 mm) Consumables for Air As per requirement 4. Plasma M/c i.e. torch tip, catalyst etc Welding electrodes As per requirement 5. (For IS2062 to IRS-M44 and IRS-M44 to IRS- M44) Lock Bolts As per requirement 6. of various sizes Lock bolts equipment 2 Sets 2 Sets 3 Sets 7. Portable grinding 03 03 05 8. machine (only dedicated grinding wheels & disc should be used) Stainless steel wire As per requirement 9. brushes SS (IRS-M44 ) plates As per requirement 10. CRF section (IRS-M44) As per requirement 11. ` Note: The class of welding electrodes for different combinations of materials shall be as per RDSO document no.G-72. WAGON MAINTENANCE MANUAL Chapter 11 Infrastructural facilities for freight yard, sick line and ROH depots: Page 12 of 15 1106 MINIMUM INFRASTRUCTURE REQUIRED FOR PREMIUM & CC EXAMINATION The following infrastructural facilities are considered essential to carry out premium examination in less than 03 hrs.  Dedicated two or more examination lines with pathways (depending upon nos. of rakes examined)  Embedded track/ Pucca pathway of 02 m width as per layout  Welding facilities and Portable welding set  Adequate illumination  Pallets for material storage/dispensing  Road between office/store and examination yard  Connectivity with FOIS  Walkie Talkie sets  Provision of MUV (e.g.Tata Ace truck) for transportation of staff and materials/equipments to examination point  Rechargeable LED head lamp WAGON MAINTENANCE MANUAL  Chapter 11 Infrastructural facilities for freight yard, sick line and ROH depots: Page 13 of 15 1107 Facilities required in Freight Examination Yards SN. DESCRIPTION Facilities Dedicated examination lines should be available in yards for CC examination with full CSR 1. Examination Line Total Pathways: CC Pathways should be provided for movement of listers and to facilitate examination staff in train examination Length – Approx 700m each to be constructed alongwith cross pathways for cross movement at the end of the line. 2. Path Ways Width – Min. 3.0 metrs and max.7.0 meters a). High Masts: High tower lights to be provided in yard for getting general illumination in lines and pathways. Atleast 04 tower in one yard are desirable. b). Normal Tower – Boom lights may also be thought of for providing suitable 3. Illumination electrical fittings on both side of boom at suitable height facilities to be provided in yard & pathways c). Lamp Post on pathways: Water proof light fittings with independent switching arrangement to facilitate train examination staff. (At an equal distance of 12/20 m). WAGON MAINTENANCE MANUAL  Chapter 11 Infrastructural facilities for freight yard, sick line and ROH depots: Page 14 of 15 Welding 4. Transformer Room Welding connections should be provided on the lighting pole for easy connectivity to the welders. The parallel earthing connections should also be given at an equal distance of 20 m interval. Fitting of welding 5. terminals at pathway Suitable capacity 02 nos. compressor units should be provided with the provision of Air Dryer for feeding air pressure to Rake Test Rigs. 6. Air Compressor Location of Rake testing Rigs fitted with air flow indicator and digital BP & FP Pressure gauges 7. Testing points should be provided at one end of the yard. Standard Tool boxes with containing of tools & gauges as recommended by 8. Tools CAMTECH should be available in yard for each gang. Provision of Field store should also be ensured for unit exchange in shifts for shift 9. Sub-Store incharges. Proper ledger should also be maintained for consumption. WAGON MAINTENANCE MANUAL  Chapter 11 Infrastructural facilities for freight yard, sick line and ROH depots: Page 15 of 15 1) Examination Gang Staff Strength Total two nos. of examination gangs may be provided with welder in each gang. ( Per shift) 2) Testing Gang – As per requirement 3) Dispatch Gang: As per requirement for Axle box felling & pressure continuity 10 etc. in Yard. 4) Rolling in exam. & Axle Box felling As per requirement for rolling in examination and operation of non contact thermal sensors for axle box feeling. Total Staff As per bench marking given in the Wagon Maintenance Manual Examination time should be minimized in the yards by providing light fittings for Examination examination of CC rakes during nights also. Required components should be 11 Time (Average) transported in advance & provided on the pathways for fitment in the required wagons. Record of average train examinations must be maintained in the yard office and Average Rake layout plan should be displayed with facilities for easy understanding of inspecting 12 Examination/Mo officials. nth Work attention Primarily work should be Sick repair along with Scrap collection form examination 13 when Gang is lines. Idle FOIS connectivity should be provided in the yard office as well as in the Divisional 14 FOIS office & trained staff should be placed for monitoring etc. Mobile work station equipped with gas plants and spares. The material handling listers should be used for material transportation in all examination lines. Material 15 Handling WAGON MAINTENANCE MANUAL