Indian Railways AC Traction Manual Volume III PDF

CHAPTER XII TRAINING AND COMPETENCY CERTIFICATES I. TRAINING 31200 Introductory Electric traction is a specialized field. Efficient operation and maintenance of the traction installations and equipment is only possible if the staff concerned have acquired an intimate kno...

CHAPTER XII TRAINING AND COMPETENCY CERTIFICATES I. TRAINING 31200 Introductory Electric traction is a specialized field. Efficient operation and maintenance of the traction installations and equipment is only possible if the staff concerned have acquired an intimate knowledge of the details of construction, adjustments and operation of the equipment. A thorough knowledge of the special rules and procedures on the part of the staff is also essential to ensure safety of equipment and personnel. These requirements call for a degree of specialized training for all categories of staff before they can be safely entrusted with the responsibility for maintenance or operation. III. 31201 Planning of Training in Advance Before electric traction is commissioned on any section, adequate strength of well-trained operating, maintenance and running staff should be kept ready for operating the services. Planning the recruitment and training of such staff well in advance is one of the most important tasks of the open line administration. This applies in particular to steam/diesel running staff who would become surplus to requirements on introduction of electric traction and hence have to be absorbed as running staff to operate electric rolling-stock. Timely release of such staff for training should be pre- planned and ensured by the Electrical Department in co-ordination with the Mechanical Department. It is also necessary to establish sufficiently in advance suitable training schools with qualified instructors and facilities for imparting the training. IV. 31202 Categories to be Trained Categories of staff for whom special training is required to be organized are generally as under- 1. Degree and Diploma holders recruited directly as Supervisors. 2. Apprentice Mechanics to be absorbed as Supervisors. 3. Trade Apprentices to be absorbed as skilled artisans. 4. Diesel/ Steam Drivers to be trained as Drivers of electric locos and EMUs. 5. Artisans and supervisory staff to undergo Refresher Courses. 6. Running staff to be posted as TLCs etc. V. 31203 Initial Training 1. Categories of staff mentioned below should receive a period of initial training in a training establishment before they are posted to working posts- a) Directly recruited supervisors. b) All categories of running staff, whether directly recruited or absorbed from steam/diesel sections. C) Skilled and semi-skilled artisan staff for maintenance. INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill d) Any other category to be approved by CEE. 2. The period of initial training for typical categories is given below, which may be modified by CEE in accordance with local requirements- a) Direct recruited supervisors (Degree and Diploma Holders)- i) Electric Loco Section 18 months ii) EMU Section 12 months b) Steam/Diesel Drivers to be absorbed as Electric Running Staff- 1) Asst. Drivers 12 weeks ii) Grade 'C' 20 weeks iii) Grade 'B' or 'A' 48 weeks c) Skilled artisans for maintenance- i) Direct recruits 60 weeks ii) To be absorbed from Diesel/Steam or Electric general services 30 weeks 3. In addition to theoretical training, the trainees should receive thorough practical training on the work they will have to perform on completion of training. In all cases they should have a period as under-study to senior and experienced staff in actual execution of the type of work they have to perform on completion of training. 4. For artisan staff the practical training should be oriented to enable them to understand and be able to carry out independently skilled work of the type covered by 'Inspection books', 'Inspection charts', 'trouble-shooting charts' and 'technical charts'. VI. 31204 Promotional Courses 1. No employee can be promoted unless he passes the trade test or other prescribed departmental test. The purpose of the semi-skilled category is to enable a man to study under the skilled man and take the trade test in due course. 2. When an employees is promoted, he should, as a rule, receive a period of training to enable him to discharge his responsibilities in the higher post e.g., a semi-skilled fitter on promotion as a skilled fitter. Such training should precede the departmental tests to determine suitability for promotion. The training should be generally on the same lines as initial training, but the period in most cases can be curtailed since the employee would already have a certain amount of background knowledge on account of his experience. Particular attention should be paid to the older men, who although very proficient in the practical aspects of their work, are unable to pass the prescribed trade tests etc. in regard to the theoretical aspects because of their poor educational background. It often happens in consequence that they are blocked for promotion although they are fit for promotion in every other respect. By paying individual attention to such men and teaching them elementary tbeory, they could be made sufficiently proficient to pass the trade tests in full. This not only ends their frustration, but boosts up staff morale as a whole. INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill VII. 31205 Refresher Courses 1. In accordance with instructions current on the subject, refresher courses should be arranged. This is obligatory for those categories of staff dealing with "safety of train operation or having daily contacts with the public". The following is an illustrative list of staff corning within the scope of these instructions: - Drivers, Asst. Drivers, Motormen, Shunters, Engine Turners, Supervisors and Artisans responsible for examination and certification of fitness of running gear of locos and EMUs. TLCs and Driving Inspectors 2. Similar refresher courses are also desirable for other categories of maintenance staff. The categories of staff for whom refresher courses are to be arranged can be decided by the General Manager in accordance with para 117(a) of the Indian Railway Establishment Manual. 3. The object of the refresher courses is to reinforce the knowledge of the staff and bring them up- to-date in regard to the latest rules and procedures and instructions regarding operation and maintenance in the light of operating experience. The duration of the refresher course for each category may be decided by CEE to suit local conditions. The duration for typical categories is given below for guidance- a) Supervisors 3 weeks b) Drivers/Asst. Drivers 3 weeks c) Artisan Staff 2 weeks 4. For categories of staff liable for inter-divisional transfers, programming of refresher courses should be arranged by the headquarters office. For staff confined to a particular division, the programming should be done at the divisional level. 5. Apart from rules and regulations, the refresher courses for running staff should lay emphasis on trouble- shooting procedures for various types of locos and EMUs. Drivers have to deal with some types of failures only rarely and hence they tend to forget the details. Though such details are given in the Trouble-Shooting, Manuals, actual drilling during the refresher course will be of great benefit. This involves repetition of the same exercise several times so as to make a lasting impression and not to be forgotten easily. 6. During the refresher courses, it will be very useful to arrange group discussions amongst the trainees on specific problems encountered during the course of work. Such group discussions will be of great assistance in view of the opportunity for exchange of information based on actual experience in working. VIII. 31206 Facilities for Training 1. Facilities have been provided on an All India basis for the intensive specialized training of officers and staff of the Electrical Department. In addition the facilities available with the different Zonal Railways have to be utilized to best advantage. 2. Training schools for Drivers are attached to major electric loco sheds. These schools should be used to a limited extent for training of artisan staff and supervisors. Apart from cut-models, charts, circuit diagrams etc. the training schools should contain ‘simulators' to demonstrate the functioning of locos, the circuit combinations resulting from operation of the master controller etc. These simulators should be used to drill the trainees in the correct method of operation and systematic trouble-shooting. 3. The 'simulator' provided consists of the HT and LT control apparatus as provided in the locos and working models of items such as pantograph, tap-changer etc. A driving cab similar to the cab in a loco is available, complete with master controller, brake controller, control switches, gauges, indicator lamps etc. From this driving position INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill the equipment in the simulator can be operated to demonstrate the functioning of the various components. By actually handling the controls, the trainees can learn the correct sequence of operation and get a 'feel' of the equipment as actually functioning. The Instructor can reproduce faults similar to those occurring in actual practice e.g., tripping of circuit breaker due to overload, earth faults, traction motor faults etc. The trainees can get familiar with the correct method of trouble-shooting as detailed in the trouble-shooting directory and by repeated practice become fully acquainted with the correct procedure. 4. In any traction training establishment, the essential equipment to be provided for instructional purposes should include the following- a) Special tools and instruments used in electric traction. b) Cut-models to show constructional details of equipment. c) Circuit diagrams, sectionalising diagrams, etc., preferably illuminated and arranged to show the sequence of operations d) Samples of damaged equipment with tablets explaining the nature of failures and preventive checks. e) Publicity boards with slogans and illustrations emphasizing safe methods of working, f) Boards illustrating 'Do's' and 'Dont's'. g) Preferably full working models. IX. 31207 Training in General and Subsidiary Rules Electric running staff as well as supervisors, when required, should receive initial training as well as refresher courses in General and Subsidiary Rules normally in the Zonal Transportation Schools, which usually have excellent model rooms to facilitate the proper understanding of the rules and systems of working. In exceptional cases when such training cannot be arranged conveniently in the Zonal Schools, CEE may authorize the training in GRs & SRs to be included in the syllabus for training in Loco Training Schools. Separate Instructors well-versed in the subject should, however, be provided invariably. X. 31208 Responsibility of Officer and Supervisors Apart from those in-charge of training establishments, other officers and supervisors in-charge of operation and maintenance should also take a keen personal interest in the training of all grades of staff attached to them. They should deem it as part of their duty to guide the trainees and watch their progress. Training is a continuous process which helps the officers as much as the trainees not only in developing contacts on a personal level, but also in understanding the finer points of operation and maintenance. A record of progress achieved, the period of training given etc. should be maintained for every trainee. XI. 31209 Examination at the end of Training All trainees should pass prescribed examination on completion of training. The scope of examination and the level of officers and supervisor responsible for examining will be laid down by CEE. The examination should have a practical bias. The examination of Drivers, for instance, should include practical tests in trouble shooting as well as correct driving and braking techniques. INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill XII. 31210 Specialized Training 1. Selected supervisors and officers from the user railways should be deputed to CLW and ICF to be associated with the production of each batch of electric loco and EMU stock. Such association of the maintenance staff at the production stage will be of great help in giving them an insight Into constructional details of the equipment. 2. Similarly when large contracts are entered into for supply of electric traction equipment incorporating new designs and technology, it is usual practice to include in the contract a clause which permits some staff of the consignee railways to be deputed to the manufacturer's works during the production stage for practical training on the equipment, so that they may get thoroughly acquainted with the operation and maintenance of the equipment, taking advantage of the training facilities available with the contracting firms. XIII. 31211 Syllabi Guidelines for syllabus of two categories of staff are given below. Syllabus on the same lines shall be prepared for all courses of trainings. Driver Grade 'C' (Conversion from Steam/Diesel) Duration: 20 weeks. A. Theoretical: (a) Basic principles of electricity - clear notions about voltage, current, power, resistance etc. - use of electrical measuring instruments for measuring voltage, current and insulation resistance - clear notions about ac and dc simple electrical circuits. (b) Principles of ac and dc generators, transformers, rectifying devices - tap-changers, lead acid and alkaline cells, relays, magnetic and pneumatic cotactors. (C) Study of power and control circuits of different types of locos used in hauling freight trains familiarization with the names, symbols and physical location of all equipment. (d) Essential details of mechanical equipment of different types of locos used in freight trains. (e) Details of pneumatic and brake equipment. (f) Procedure for preparation of locos for service - principles of driving, acceleration, speed control, use of gradient marks, procedure to be followed at neutral sections, correct use of electrical and mechanical brakes. (g) Study of rules specially applicable to electric traction. (h) Safety precautions, prevention of wheel-slip and parting. (i) Procedure for obtaining emergency power block for roof inspection. 0) Rules regarding fire fighting in electrical installations and practice use of common types of fire extinguishers. (k) Study of standing instructions. (B) Practical: (a) Work with the maintenance staff to get familiar with equipment. INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill (b) Detailed study of trouble-shooting directory for each type of loco and actual practice of each case. (c)Practice inspection of outgoing and incoming locos in shed. (d)Driving under the supervision of a senior and experienced Driver after learning road. 2. Supervisor (Electric Loco) - Direct Recruits - Degree or Diploma Holders Duration.: 18 months. A. Theoretical: (a) General principles of 25 kV traction Installations and rolling stock. (b) Detailed study of mechanical and electrical details of all types of locos in the railway including bogies and suspension, power transmission, braking system, hauling capacity, power and control circuits and details of all traction and auxiliary equipment. Become thoroughly familiar with circuit diagrams, symbols and physical location of all equipment. (c)Maintenance organization in the shed- section-wise distribution of work with particular reference to responsibility of each supervisor in the shed, functioning of PPO, Maintenance schedules, inspection books, inspection chart, technical charts etc. (d)Work done during POH of loco. (e)Rolling-stock operation-outstation maintenance, loco links, control over running staff, Traction Loco Control. (f)Procedure for indenting and accountal of stores T & P Register. (g)Rules and regulations -Factories Act, HOER, Payment of Wages Act, Workmen's Compensation Act, Leave and Pass Rules, Rules for Overtime Working etc. B. - Practical. (a) In the shed some time should be spent in each section to study details of maintenance carried out by designated workmen and some time to understudy the section supervisor. When attached to E1 and M1 sections, the trainee should undertake trouble-shooting independently. (b) In the POH shop, in a similar manner as above in each section. II. COMPETENCY CERTIFICATES XIV. 31212 Authorized Person An "authorized person" is one who is duly authorized to perform specific duties pertaining to his employment, the authorization being made by an official of the Railway Administration empowered for that purpose. XV. 31213 Competency Certificate Each authorized person will be given a "Competency Certificate", defining the works which he is authorized to carry out after he has been trained, examined and found fit. INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill The following categories of rolling stock staff shall be issued with the certificates by the official indicated against each category after written/oral test as shown: 1. Asstt.Driver (Elec. Loco) TR-10 DEE(RS)/DEE(OP) after Written, oral and practical tests as prescribed. 2.Driver (Elec. Loco) TR-11 -do- 3. Motorman (EMU train) TR-12 -do- 4. Shunter/Engine Turner TR-13 -do- XVI. 31214 Period of Training XVII. XVIII. The period of training mentioned in the following paragraphs may be modified, If considered essential by CEE, taking local circumstances into account. XIX. 31215 Drivers, Asstt. Drivers and Motormen XX. XXI. Drivers, Asst. Drivers and Motormen should undergo courses of training and tests indicated below before they are issued with the Competency Certificates:- XXII. 1. A prescribed course of training in General and Subsidiary Rules in the Zonal Training School or other approved training establishment followed by a written. oral and practical test. 2. A course of training as indicated in paras 31203, and 31211 in the Electric Loco School in the operation of the particular types of locos/ EMUs he is expected to work, including trouble- shooting procedure to be followed by written, oral and practical tests. 3. Training for a period of one month to "learn the road" in the specified section, at the end of which the employee should sign a declaration that he is fully conversant with the road. 4. Practical training for a period of 2 months in the actual driving of the particular type of Loco/EMUunder the supervision of a qualified Driver or Driving Instructor followed, by a driving test by Sr.DEE (RS)/Sr., DEE(OP). 5. Prescribed medical examination. Fresh training to the extent authorized by CEE and tests as per items (2) and (4) above will be required before the employee is allowed to operate any other type of Loco/EMU. XXIII. 31216 Register of Certificates XXIV. XXV. A register of Competency Certificates shall be maintained in the office of every supervisory official, as per proforma given in Annexure 12.01, showing all staff working under him who have been issued with the Certificates: 31217 Service Record An entry should be made in the service sheet of every employee who has been issued with a Competency Certificate. XXVI. 31218 Inspections XXVII. XXVIII. During inspections Officers and Supervisors should make it a point to check the certificates in the possession of the various staff and also test-check their knowledge of the rules pertaining to their work. INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill