(Govt. of India) (Ministry of Railways)

 

 

 

STANDARDISATION OF INFRASTRUCTURAL FACILITIES FOR CC RAKE MAINTENANCE DEPOTS ON

IR DEPOTS

 

 

 

 

 

 

 

 

IRCAMTECH/M/GWL/2017/STD. CC Rake Depot/1.0

MAY-2017

 

 

MAHARAJPUR, GWALIOR—474020

 

 

 

FOREWORD

 

As per Task Force Committee’s suggestions issued within the month of January-2017, it was proposed to develop normal infrastructural services required for CC Rake upkeep Depots. For this goal, audit of some CC Rake depots was deliberate and a crew of CAMTECH officers was assigned the work for making ready report. On the idea of subject realities, the crew was instructed to develop report on above required infrastructure.

 

It would even be worthwhile to say right here that for strengthening of infrastructure for freight examination yard, CAMTECH had already ready studies in 2003 & 2008 analyzing factual necessities for freight inventory upkeep in open line. After detailed research by CAMTECH crew, it’s revealed that infrastructural necessities assessed in earlier studies and suggestions given prior to now are nonetheless thought-about to be helpful for freight examination yards.

 

Hence on the idea of previous research on the topic and audit performed in current months, a report has been ready by the CAMTECH not solely with the efforts of CAMTECH officers but in addition from no. of Railway officers and supervisors from Zonal Railways. In this report steps have been prompt for enhance in inhabitants of CC Rakes and in enchancment in high quality of prepare examination.

 

In this report, the infrastructure services thought-about important are; Standard size CC Rake examination traces with specified pathways (relying upon no. of rakes examined), Concrete path means & cross pathways, welding services and moveable welding units for MS & SS welding, sufficient illumination degree, pallets for materials storage/dishing out, Road between workplace/retailer & examination yard, FOIS connectivity, Mobile/walkie-talkie units, provision for transportation of employees and materials/equipments to examination factors, PPEs and rechargeable LED head lamps and many others.

 

 

 

(A.R.Tupe) Executive Director CAMTECH, Gwalior

 

 

 

 

PREFACE

 

 

 

Task Force Committee vide his Report No.Jan-2017 had instructed CAMTECH to recommend the Standard Infrastructural Facilities required for CC Rake Maintenance depots..

 

 

CAMTECH personnel visited Mughalsarai/Eastern Railway, New Katni & STA CC rake depot/WCR and Khanalampur/NRLy, TKD/NRLy, Shambhupura/WRLy and interacted carefully with officers and supervisors. Data was additionally acquired from GIM, NKJ & STA

 

 

We are sincerely grateful to all officers and supervisors who gave their options, particularly Sr. DME/Mughalsarai and DME/NKJ, ADME/STA, ADME/Khanalampur, ADME/TKD, ADME/COR for his or her useful feedback.

 

 

Emphasis on this report has been given to have upkeep with mechanized materials dealing with services.

 

 

(Okay.P.Yadav) Director (Mechanical)

CAMTECH, Gwalior

 

CONTENTS

 

Description	Page No
Foreword	i
Preface	ii
Contents	iii
1.0      Terms of reference	1
2.0       Objective	1
3.0      Methodology adopted	1
4.0      Observations	2
5.0       Recommendations	5
6.0       Basis for Major suggestions	9
7.0       Cost profit evaluation	11
Annexures
Annexure I: Proposed Lay out below lined shed	12
Annexure II: Wagon defect consideration	14
Annexure III: Infrastructural services together with M&P for CC Rake examination in Yard	19
Annexure III-A: Hydraulic CBC Lifting crane	23
Annexure III-B: Specifications for two T capability hydraulic CBC lifting crane	24
Annexure III-C: Specifications for Hand Operated hydraulic unit for removing of CC pad & EC pad	25
Annexure III-D: Specifications of Hand Operated hydraulic unit for removing of Springs	26
Annexure IV: Diagnostic System of TKD container Yard	27
Annexure V-A: Trial performed at NKJ Yard	29
Annexure V-B: Trial performed at PP Yard Bhilai	30
Annexure V-C: Flow Chart indicating sequence of actions	31
Annexure VI-A: Approx Cost break up for proposed services	32
Annexure VI-B: Savings and benefits of proposed services	35
Annexure VII: Specifications of abrasion resistance granolithic concrete flooring	37
Annexure VIII: Overhead lighting fittings	40
Annexure VIII-A: Lightning association for CC Rake examination Yard	41
Annexure VIII-B: Electrical Junction Box association	44
Annexure VIII-C: Electrical Panel and Junction Box	45
Annexure VIII-D: Proposed Welding Transformers	46
Annexure IX: Photograph of Multi-utility Vehicles	48
Annexure X: Check List for CC Examination Point and Sick Line	49
Annexure XI: Recommended Illumination Level as per IS: 3646 (Part-I)-1992	53
Suggestions acquired throughout Seminar at CAMTECH on 28.04.2017	54

 

 

 

STANDARDISATION OF INFRASTRUCTURAL FACILITIES FOR CC RAKE MAINTENANCE DEPOTS

 

1.0       TERMS OF REFERENCE

 

 

Task drive committee vide report No. Jan-2017 directed CAMTECH to standardize infrastructural services for CC rake examination upkeep depots..

 

                        OBJECTIVE

 

 

To lay down the requirement of services in CC rake upkeep depots analyzing CC rakes of BOX-N, BCN, BCNHL, BTPN & BLC in order to:-

• Increase the provision of rakes by discount in whole detention of rake from placement to removing together with examination and detachment of sick
• Improve in-service reliability of CC rakes

 

                        METHODOLOGY ADOPTED

 

 

• The following studies/proposals have been considered:

 

 

• The CAMTECH’s earlier report no. CAMTECH/2003/M/INF- STD/1.Zero of August 2003 for Standardization of Infrastructural services for Freight Stock upkeep has been
• The report of committee of CRSE WR and CRSE WCR no. 2003/M(N)951/22 dt.21-08-06 for tank wagons and lined
• The Report on World class services required in Freight depots-Jan- 2008.

 

• TKD yard was collectively visited with SSE/Incharge to check the upkeep philosophy and the upkeep infrastructure for CC rakes of container flat

 

 

 

• Khan Alampura yard was collectively visited with SSE/Incharge to check the upkeep practices and the upkeep infrastructure for BCNHL CC
• Shamboopura yard/WRly was additionally collectively visited with SSE/incharge to check upkeep practices and upkeep infrastructure for BCNHL CC

 

• Satna Yard/WCRly was additionally visited with SSE/incharge and audit performed for availability of infrastructure and upkeep

 

• Consultations have been held with officers and supervisors throughout seminar at CAMTECH on 28.04.2017 earlier than framing the suggestions.
• The services have been labored out for yards dealing with minimal 5 CC rakes per

 

• OBSERVATIONS : It was noticed throughout audit of above CC rake upkeep depots that the services presently obtainable in a lot of the depots aren’t as per norms in respect of the next –

 

2. Concrete Pathways : Most of yards aren’t having normal concrete pathway between the nominated traces for CC rake upkeep. Material must be transported with listers or hand trolleys and many others and moveable welding units are additionally required to be moved for CC rake. Difficulties are being confronted for such actions. Minimum 2.Zero meter vast pathway is important for straightforward motion of fabric and

 

5. Distance between two examination traces: The really helpful distance between two examination traces in yard is 5.26 meter. But, in case of CC examination traces, additional house is required for building of pathways for motion of listers, hand trolleys and many others. Considering above components, a transparent distance of seven.5 meter (centre to centre) between tracks has been proposed. Extra house shall be required as a consequence of obstruction of OHE masts, lighting poles

 

1. Pit line : It is noticed that pit line will not be usually obtainable in yard sick traces. The pit line is required for brake gear repairs. In case of tank wagons, pit line is important to hold out valve repairs and different associated

 

1. Road connectivity: – During audit it was additionally revealed, that many depots aren’t nicely linked to the roads and cross pathways. Paved street connecting examination yards and yard sickliness to municipal street is important for transportation of fabric &

 

 

 

1. Welding services :- Welding work is required to be achieved at CC rake examination yard to keep away from sick marking. It is due to this fact mandatory that welding line underground/ above grounded must be obtainable with terminal packing containers on the complete size on different line at an interval of 20

 

1. Lighting association :- The illumination degree is mostly poor within the yards. CC rake examination yards have to be supplied sufficient lighting preparations. Lighting requirement for working of employees are greater than these for normal working. The really helpful illumination is given within the annexure-XI.

 

1. Material Handling services:- The materials dealing with services for CC rake examination yards had been namesake solely within the type of hand trolleys, pickup vans for bringing materials from retailer. In the most important depots, Road vans also needs to be

Observations throughout audit in CC Rake examination Yards

1.       TKD/NRLy CC Rake upkeep Yard

1. At AGC finish one rolling hut is supplied for 04 traces fitted with photo voltaic gentle. Rolling in examination lighting association must be supplied for every entry
2. 02 Staff must be deputed for rolling in examination on both
3. The situation of pathways must be good for straightforward
4. Cross pathways are additionally required for transportation of
5. Sufficient tower lighting must be supplied within the yard for normal illumination.
6. Tool package must be obtainable in device bag for every

 

2.       Khanalampura/NRLy CC Rake upkeep Yard

1. MB finish rolling in examination lighting association must be
2. General illumination in yard will not be obtainable. Sufficient tower lighting must be
3. Precast paver blocks must be supplied between pathway and rail line for straightforward placement of hydraulic
4. No lighting pole supplied for pathways to facilitate examination employees. This association is
5. Hinge kind doorways are being changed with sliding kind doorways in yard for BCNHL
6. Retrofitment is happening for repairing of doorways in

 

 

 

3.       Shambhupura/WRLy CC Rake upkeep Yard

1. LED gentle is considerad to be helpful for below gear
2. BCNHL/BOXNHL wagons are getting broken throughout loading and unloading in
3. Body work (patch work & welding work on wagons must be added in work distribution given at desk 3.Four of chapter Three of wagon upkeep
4. Running of CC Rakes on invalid BPC to be strictly

 

4.       Satna/WCRLy CC Rake upkeep Yard

1. Cross pathway to be constructed in yard for motion of autos
2. Separate traces to be nominated for CC rake
3. Platform with cat stroll for upkeep and shutting of BCNHL wagon doorways must be
4. Separate sick line to be supplied to attend sick
5. Covered Rolling in /Rolling out huts with lighting facility for employees to could also be supplied .
6. Running of CC Rakes on invalid BPC to be strictly

 

 

 

 

5.                   RECOMMENDATIONS:

 

For     main      CC     rake     examination      yards     dealing     predominantly           with BOXN/BCN/BCNHL,BTPN & BLC wagons, the services can be as below:-

 

5.1 The Schematic Layout of the Proposed  CC rake upkeep  yard shall be as per Annexure-I (A ) and I (B). The yards dealing with upto 10 rakes per day  shall have two Examination Lines of 750 meter every, one line for retaining sick wagons and one line for retaining match wagons launched from Sickline. The mega yards coping with greater than 10 rakes shall require doubling of those services

i.e. Four examination traces and a pair of traces for sick wagon and a pair of traces for match wagons.

 

 

5.2. Sick wagons and wagons due for ROH/POH shall be amassed on the sick yard line and thereafter pushed to sickline every time the occasions permits.

 

• The Fit line shall be used to maintain wagons launched from the sickline for recouping the shortfall on account of the sick wagons indifferent from the rake. The match wagons shall be connected in a single formation on the head of the rake with the assistance of shunting

 

• Each Examination line shall be of 750 Mtr. every to facilitate creation of gaps and the centre distance between the Examination, Sick and Fit line shall be 7.5 Mtr. to make sure free motion of fabric dealing with equipments and minor consideration. All tracks so far as attainable must be in a straight line for a distance of 720 m

 

 

 

COVERED SHED WITH EOT CRANE

 

 

Examination Line

 

Sick yard Line                             Granolithic Concrete Flooring

Examination Line Fit wagon Line

Line no. 1

 

Line       2

 

Line no. 3

 

Line no. 4

 

 

Spare traces

• For the supply of Goliath Cranes, there must be no OHE wiring over the Examination traces/Sick Yard line/Fit Wagon Line which shall be handled the EOT Crane. Top wiring at each the ends of the prepare examination line can, nevertheless, be supplied for dropping the rake and for ready for crew/loco after launch.

 

• (a) A devoted diesel shunting engine shall be used for placement of rakes in examination traces if the rake is acquired with electrical

 

(b) A rail cum street shunting automobile with capability to haul 30 empty wagons shall be used for creating gaps between wagons requiring detachment on account of POH/ROH/Major repairs. The automobile shall even be supplied with compressor and rake take a look at rig for air brake testing of formations.

 

• For yards dealing with upto 10 rakes per day, 7 EOT cranes of 30 tonnes lifting capability, 30 mtrs. span and 720 mtrs. travelling shall be supplied. Each wagon shall be lifted with the assistance of EOT Cranes through the use of specifically designed slings for lifting from Axle Box. The mega yards analyzing greater than 10 rakes per day shall have 14 EOT

 

• At current there isn’t a expertise with Railways for dealing with BOXN/BCN/BTPN & BLC wagons with Goliath cranes. As such the Goliath crane will be supplied in a single yard for trials by way of effectiveness and maintainability.

 

 

 

 

 

 

 

• Major sickline with all Infrastructural services would stay connected and adjoining to freight examination

 

• The requirement of M&P is given in Annexure-III. In order to expedite repairs In-Situ, sufficient variety of materials dealing with autos and multi-utility autos shall be

 

• For materials dealing with, 4 wheeler pickup vans like TATA ACE will be
• These autos shall be retro-fitted with a small DG set cum Diesel pushed welding plant, Gas chopping equipments, moveable jacks for altering EM pads, spring altering gear, moveable compressor and hand instruments, and many others. along with this, the van shall have sufficient spares instruments and equipments instruments and few incessantly required supplies like pins, washer, nut bolts, key, and many others. required in the course of the course of examination. Nominated employees attending to those defects shall additionally transfer by this van. Two focus gentle will likely be mounted on both facet of the automobile together with one excessive focus headlamp. These lights shall be swiveling kind. Picture of 1 such automobile is enclosed as Annexure-IX
• Hand operated hydraulic unit with jacks of capability 5 tons & 20 tons could also be mounted on these autos for removing of C.C. pad, E.C. Pad and comes. The sketch and specification of hydraulic CBC lifting

 

 

 

crane and hand operated hydraulic unit for removing of C.C.pad, E.C pad and spring is enclosed as Annexure-III-A to D

 

• The full space of the examination yard shall be supplied with abrasion resistance granolithic concrete flooring and ballast free embedded monitor to ease motion of autos and materials dealing with equipments. The specification of Abrasion Resistance Granolithic Concrete flooring is enclosed as Annexure- VII.
• Illumination: The illumination round yard must be supplied by excessive depth tower lights. The specification of sunshine fittings and lighting association over shed space is enclosed as Annexure-VIII-A
• In between sick yard line and examination line, electrical panel with junction field at a distance of 30 meter shall be supplied as proven in Annexure VIII-B. Details {of electrical} panel and junction field are enclosed as Annexure VIII-C. For welding moveable welding units shall be supplied. The specification of proposed welding transformers are enclosed as Annexure VIII-D &
• Effective communication system ideally CUG cell phones or walkie talkie units shall be supplied throughout groups in the course of the examination between Supervisors, TXRs, drivers of EOT Cranes, drivers of multi utility autos and shunting
• A system for place monitoring of EOT cranes, multiutility autos and rail street automobile utilizing energetic RF ID system to be supplied for higher monitoring by means of yard

 

• In order to cut back physique restore in sickliness it is suggested that in POH:

 

• There shouldn’t be any partial and periphery repairs on the ground of wagons throughout POH. The flooring must be changed by 100% new flooring in order that it could possibly final from POH to POH thereby decreasing the load of patch restore works in
• With the rise in common age of BOXN/BCN wagons, a lot of the BP prepare pipe and department pipe are getting perforated day by To

 

 

 

cut back sick marking on this account, the alternative of 100% prepare pipe must be a rejectable defect throughout alternate POH.

• There are directions for dropping of all CBC throughout POH which have to be ensured and no coupler/draft gear past condemning restrict must be
• The broken/corroded facet stanchions must be modified fully in workshops moderately than
• The damages to the highest coping between stanchion no – 3 & Four is to the extent of 28%. To cut back these damages, alternative of high coping between stanchion no. -3 & Four together with stanchion, door mediator and doorways must be within the type of an entire two pillar

• The siding homeowners who’re loading and unloading with the assistance of pay loaders should be disciplined because the increase of the pay loader and its tyres are hitting the wagons. This will be changed by, both conveyer loading system or hopper system.
• The sequence of actions as indicated in Annexure –V-C must be
• A complete contract for day after day maintenance of the yard is really helpful for main and mega yards. This contract ought to cowl objects like scrap lifting and bush chopping within the periphery of the
• A working contract for petty repairs pertaining to shed and flooring of the yard together with civil and electrical engineering works can be really helpful. This contract shall be monitored by subject officer of Mechanical
• A working contract for upkeep of all main M&P resembling EOT cranes, compressor, autos, welding units, hydraulic jacks can be

 

6. BASIS FOR MAJOR RECOMMENDATIONS:

 

 

• In the current system of working it’s not attainable to have a detachment free prepare examination yards due to following causes:-
  • Roughly 46 to 59% detachment of wagons are on account of ROH/POH. At current a lot of the workshops aren’t turning out wagons after POH within the type of full rake. Moreover even when an entire rake is turned out, the integrity of rake is tough to keep up as Four to five wagons get indifferent for sick marking as a consequence of

 

 

 

numerous causes throughout every examination. Apart from this, rake integrity can be disturbed due to alternative of embedded empties even when the rake will not be due for examination.

• During examination of wagons, on a median 37 to 49 % of sick detachments happen on account of physique defects, notably in case of BOXN wagons. These defects require panel welding/flooring restore/patches on pillars/construction, which usually takes 2 to six hours on a median for rectification in sickline. Moreover, as per current follow ‘petty repairs’ involving no more than eight man hours are carried out in Examination Yards. Instead of this follow it is suggested that repairs which will be carried out in lower than 10 minutes solely must be attended to in-situ, remainder of the wagons must be indifferent. If we plan to rectify even main defects IN- SITU full rake will likely be unnecessarily

• As it’s not attainable to have detachment free prepare examination, these two attainable options for alternative of sick/POH/ROH wagons are :-

• Carrying out shunting as per present
• Lifting of full sick/ROH/POH wagons with the assistance of Goliath/EOT cranes

It has been discovered that most detention takes place on account of shunting. Even if shunting neck is free, every detachment can take 30 to 45 minutes, whereas in the course of the trials carried out at PP yard, Bhilai and NKJ yard, it has been discovered that one wagon will be lifted and positioned in one other line with the assistance of cranes in about 6 to 10 minutes. So with a purpose to obtain, the target of decreasing the whole detention of rake to lower than 6 hours, lifting of wagons is probably the most appropriate different.

• The two attainable options, for lifting of full wagon and inserting it on a specifically nominated sick yard line are:

• Covering the whole examination yard with the lined shed and offering numerous EOT
• Keeping the shed open and offering Goliath

Out of those two options, Ist different additionally gives further benefit of bettering the working situations making all of it climate examination depot with higher illumination. Moreover at current, Indian railway will not be having any

 

 

 

 

experience of handling BOXN/BCN wagons with Goliath cranes and the cost of shed with EOT crane is comparable to that of Goliath cranes. (The cost of providing covered shed over an area of 720 m x30 m i.e.21600 sqm is estimated to be around 31.2 Crore Rupees and the cost of 7 EOT cranes is Rs.5 Crore, thus the total cost is around Rs.36 Crore, whereas the cost of 3 Goliath cranes is Rs.27-30 Crore). So keeping in view the overall benefit, favoured Ist alternative of covering the complete examination yard with the covered shed and providing a number of EOT cranes.

 

 

1. COST BENEFIT ANALYSIS

 

 

Estimated cost of the recommended facilities for a major yard handling upto 10 rakes per day is 46.77 Crores as per details given in Annexure- VI-A. It has been estimated as per details given in Annexure-VI-B that by providing these facilities, 4.65 rakes would be additionally available for traffic use per day per yard (handling 10 rakes per day) These 4.65 rakes can generate an additional net annual revenue of Rs.74.63 Crores to the Railways.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

LAYOUT FOR WORLD CLASS FREIGHT TRAIN EXAMINATION YARD

Annexure -I (B)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Toilet   Computer Room   JE/SE Room   Yard Control Room Stairs   Admn. Room   SSE Room   SSE Office   Meeting Room   Toilet     Compressor Room     Store and Tools Room Stairs   Staff Room     Battery Room     DG set Room     Garage     Parking     Heavy material Stock yard and scrap yard Corridor

Motrable Road                                                                                        Motrable Road

 

 

 

Heavy Stock yard

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Note:

All dimensions are in meters Drg. not to scale

Yard

 

 

 

 

 

 

Yard

 

 

 

 

 

 

 

 

 

 

 

Yard

 

 

 

 

Annexure-II

Wagon defects attention in present scenario and with proposed facilities

 

		Present Scenario		With proposed facilities
Sl No.	Defects	Examinati on line	Sick line	Examinatio n line	Sick yard line	Sick line
A	Wheel Defects
1	Deep Flange		√			√
2	Hollow Tyre		√			√
3	Skidded		√			√
4	Sharp Flange		√			√
5	Thin Flange		√			√
6	Root of Flange		√			√
7	Grease Oozing/Warm box		√			√
B	Air Brake Defects
1	DV replacement	√		√
2	Angle cock replacement	√		√
3	COAC safety Bkt. Replacement	√		√
4	Dirt collector replacement	√			√
5	Air hose replacement	√		√
6	Air hose palm end replacement	√			√
7	MU washer replacement	√		√
8	Air hose carrier replacement	√		√
9	Brake pipe	√			√

 

 

 

		Present Scenario		With proposed facilities
Sl No.	Defects	Examinati on line	Sick line	Examinatio n line	Sick yard line	Sick line
10	Piston stroke adjustment	√		√
11	Auxilliary reservoir Bkt. Replacement	√			√
12	Brake Cylinder Leak		√		√
13	Branch Pipe Leak		√		√
14	AR Tank Leak		√		√
15	Common pipe Bracket		√		√
C	Bogie Defects
1	Brake block replacement	√		√
2	Brake shoe replacement		√		√
3	Brake shoe key replacement	√		√
4	Split pin replacement	√		√
5	End pull rod pin hole adjustment	√		√
6	Push rod replacement	√			√
7	Equalizing lever replacement		√		√
8	Outer spring replacement	√		√
9	Inner spring replacement	√		√
10	EM pad	√		√

 

 

 

		Present Scenario		With proposed facilities
Sl No.	Defects	Examinati on line	Sick line	Examinatio n line	Sick yard line		Sick line
	replacement
11	Brake beam pocket liner replacement		√		√
12	Column plate		√		√
13	CC pad		√		√
14	Snubber Spring		√		√
15	Snubber Wedge		√		√
16	Slope Liner		√		√
17	Side bearer Housing		√		√
18	Side bearer Spring		√		√
19	Adapter Cant	√			√
20	Bottom spring plank		√		√
D	Brake Gear defects
1	SAB replacement	√		√
2	SAB gear bush & roller Bkt. Replacement	√			√
3	Control rod replacement	√		√
4	Load tie rod replacement	√			√
5	Empty tie rod replacement	√			√
6	Sleeve nut replacement	√			√
7	L/E bkt & Handle replacement	√		√
8	Short pull rod replacement	√		√
9	End pull rod	√		√

 

 

 

		Present Scenario		With proposed facilities
Sl No.	Defects	Examinati on line	Sick line	Examinatio n line	Sick yard line		Sick line
	replacement
10	Horizontal lever safety Bkt. Replacement	√			√
11	Brake Beam		√		√
12	Low Bottom (22WM)		√			√
E	CBC /Draft Gear Defects
1	Knuckle changing	√		√
2	Knuckle pin changing	√		√
3	Knuckle pin APD	√		√
4	Lock lift assembly replacement	√			√
5	Lock replacement	√		√
6	Operating handle replacement	√		√
7	Bearing Pease replacement	√			√
8	Stricker casting wear plate replacement	√		√
9	Shank wear plate replacement	√		√
10	Draft Gear		√			√
11	CBC Coupler Body		√			√
12	Yoke		√			√
13	Yoke Pin Support Plate Rivets		√		√

 

 

 

		Present Scenario		With proposed facilities
Sl No.	Defects	Examinati on line	Sick line	Examinatio n line	Sick yard line		Sick line
F	Under Frame & Body Defects
1	Door fitting replacement (minor)	√		√
2	Door fitting replacement (major)		√		√
3	Hand Brake wheel repair (steering handle replacement)	√		√
4	Hand Brake rod system		√		√
5	Foot step replacement	√		√
6	Side stanchions		√		√*	√
7	Under frame channel		√		√*	√
8	Floor		√	√ #	√*	√
9	Body		√	√ #	√*	√
10	Door		√	√ #
11	Top Pivot		√			√
	#. Repair of very minor nature * Repair of medium nature.

 

 

 

Annexure-III

 

Infrastructure facilities including M&P for CC rake Examination Yards

 

 

Description		Recommended Requirement
Trains examined per day (average)		5-10 rakes per day
(A)	INFRASTRUCTURE
1.	Total lines required	2 Lines for examinations and one line for sick wagon and one line for fit wagon and two lines for shunting and traffic use.
2.	Center       to        center distance between two lines	7.5 m centre to centre distance to be provided between two lines for enabling proper examination and assure staff safety from movements & for material movements.
3.	Flooring in yard	The complete area of examination yard i.e. 30 x 750 meter will be provided with abrasion resistance granolithic concrete flooring and ballast less embedded track, to ease movement of vehicles.
4.	Covered shed	The complete area of examination yard i.e. 30 x 720 meter will be provided with covered shed.
5.	Paved road for truck movement.	Five meter wide paved road connection to Municipal road from both ends of the yard.
6.	Length of line	Rake length plus fouling mark i.e. approx. 750 meter.
7.	Supervisors Room	One room of size 5mx7m.
8.	Computer room	One room of size 10mx7m
9.	Staff room	One room of 6mx10m at each end.
10.	Rolling in/out huts	One no. (3mx3m) at each end with spot light.
11.	Field store + Tool room	Should be the size of 10mx12m
12.	Compressor Room	6mx8m room for each compressor.
13.	DG room	6mx8m room for DG set
14.	Vehicle parking room	15m x 7m
15.	Yard control room	5m x 7m
16.	Battery charging room	As per requirement depending on the number and usage of material movement equipment.

 

 

 

 

(B)	LIGHTING
1.	Tower light with adequate height around covered shed & spare lines	Four tower lights (20 meter height) per examination yards.
2.	Heavy-duty      portable rechargeable torches.	6 nos.
3.	LED head light	One per staff + 50 % spare
4.	Overhead light	Metal halide lamps OR LED Lamps Details as per Annexure-VIII-A
(C)	MACHINERY AND PLANT
1.	Shunting engine	01 no
2.	EOT        crane                   with pendant                 and    remote control facility	07 nos (If proposed)
3.	Welding                 Plant (portable)	06 nos Details as per Annexure-VIII-C
4.	Rail cum road vehicle (capacity to haul 30 empty wagons)	01 no (If proposed)
5.	Arc welding set (Mounted on trolley)	Two nos. Details as per Annexure-VIII-C
6.	DG set 250 KVA (for compressor,     light    & welding)	One nos
7.	DG set 500 KVA (for cranes)	One no. (If proposed)
8.	Electric/DSL Compressor (500 CFM) (Required for brake power testing of air brake train)	One no.
9.	Gas cutting set	1 per examination batch
10.	Protective         clothing with Helmet & Gloves	As per requirement
11.	Welding      Apron      & welding glass	As per requirement
12.	Rake Test Rig	One per line & one standby

 

 

 

13.	Hydraulic Jacks for wagon lifting, Bolster spring changing, Side Bearer Spring changing for HA and CBC wear plate changing.	5 Jacks each of 10 Tons, 20 Tons and 25 Tons.
14.	MUV   (Four    wheeled Tata Ace truck )	02 per line
15.	Staff van	2 per yard
16.	Pick     up     van     (for movement                 from outside)	2 per yard
17.	Truck	02
18.	Lister truck	4 nos.
19.	Road mobile crane (15 Ton capacity)	One no.
20.	Hydraulic CBC lifting crane (2 T capacity)	01 Details as per Annexure-III-A
21.	Hand trolley	1 per line
22.	Mobile                              (wheeled) platforms     to                     attend doors etc	1 per line
23.	Portable drill machine 12 mm	As per requirement.
24.	Bending machine	Not required	One per yard
(D)	MISCELLANEOUS
1.	Storage      rack                  with pigeon holes	As per requirement
2.	Rack with Locker	One locker per staff
3.	Rack with Locker	One locker per staff
4.	Plain paper fax with P&T line	One per depot
5.	Laptop	As per requirement
6.	Walkie      Talkie      set/ Mobile phone	25 nos
7.	Railway Telephone	As per requirement
8.	P&T Telephone	One per depot

 

 

 

9.	Computer, with printer, Scanner, UPS with preloaded software & modem.	03 no.
10.	C&W Office furniture	As per requirement
11.	Railnet       Connection/ (Internet  Connection if Railnet is not available)	As per requirement
12.	Xerox     Machine               for printing, copying with stabilizer	One per depot
13.	PA system	One per yard

 

 

 

Annexure-III-A

 

 

 

Annexure-III-B

 

 

 

Annexure-III-C

 

 

 

 

 

Annexure-III-D

 

 

 

 

Annexure IV

 

 

The diagnostic systems of Northern Railway at TKD yard :

 

 

1. Way Side Data Collection Systems: are proposed to be installed at entry to and exit from TKD yard. The system shall be in the form of modularized set of instrumented detectors. These equipment shall pick up data of moving trains and using standard comparators identify defect locations. Data collected from this system shall be analyzed at the central location in the yard. Using Wheel Data Management system Solution Software (WDMS) and through network this result shall be provided to the forth coming train examination gang. The system shall be capable of indicating the wheel condition and any part requiring replacement beforehand.

 

2. Acoustic Bearing Detectors: This shall provide information about bearing condition and notify bearing that have internal defects related to cup cone or rollers and prevent axle boxes before they become hot. The system shall have an automated alarm notification with self-diagnostics.

 

3. Low Hose Detectors: This equipment is for identification of hanging parts affecting bearing performance. This shall have a non-contact measurement system to identify low hanging parts. It shall employ infrared light curtains to identify each hanging part by measuring the distance between the part and top or rail. This shall give graphical display of hanging parts and automated alarm

 

4. Wheel Impact Load Detector: The equipment shall detect the condition of wheel with respect to flat tyre, its magnitude and send audio-visual alarm to the centralized control system, if the limits are more than the prescribed. This will enable the maintenance staff to plan the wheel change in

 

 

 

5. Weigh In Motion (WIM) with load imbalance and overload detection: This shall be used in consumption with WILD and shall provide information for overload or load imbalance conditions.

 

6. Wheel profile recording detector: This equipment shall be able to measure the bogie parameters such as vertical & lateral forces, vertical and lateral movement while the wagon is in motion and shall be able to guide the maintenance staff about the bogie condition with respect to the laid down maintenance

 

7. Machine vision equipments consisting of brake equipment monitor: This system shall measure and monitor the brake blocks, especially its wear.

 

8. Yard Center Database Integration: There shall be central control integrated system for linking all performance monitoring system at the TKD yard center in the wheel data management system (WDMS). The information shall be displayed in a useable format for maintenance personnel and management. It will include a web based interface and integrate all detectors in the wayside detector

 

9. In-situ Wheel Changing: Mobile hydraulic jacks with wheel changing facility –the equipments will be hydraulically operated and able to lift the loaded wagons to a height so that the wheels can be taken out axially instead of rolling out on the track. Adequate safeguards for fail safe operation shall be available for operation safety. System shall be capable of handling loaded wagons. Suitable forklifts trucks to transport wheels from a central location shall be provided.

 

 

 

 

 

 

 

 

Annexure –V-A

 

 

Trial Conducted at NKJ yard

 

 

[ As per CAMTECH Report No. CAMTECH/2008/M/W/Infra/1.0 Jan-2008 ]

 

Sl.no.	Activity	Time taken
1	Attaching of diesel engine in front of incoming AC loco, taking line block, checking of the load by C&W staff, attention to minor repairs and brake testing, chalk marking of wagons requiring detachment.	1’. 0.0”
2	Releasing line block and Pulling the rake to ROH shed	0 ‘ 15”.
3	Total time for bringing detachable wagons under position of EOT cranes	0’54”
4	Creation of gap between individual wagons	0’38”
5	Time taken for detaching/ replacement of 13 wagons	1’44”
6	Recoupling of load, pulling the load ahead, detaching diesel  engine,  creation of air    pressure and despatch of load	32 “
7	Total time taken	5’.03”

 

It can be seen from the table in para 7 that replacement of one sick wagon by a fit wagon takes 8 minutes (average).

There was a substantial avoidable detention in this trial scheme due to limited length (100 meters) of ROH shed and limited number of EOT cranes (2 numbers) and their limited capacity (15 T).

If entire rake is placed at one go inside the covered shed of 720 meters, the required gaps can be created earlier and there would be a saving of 54 minutes.

 

 

 

 

 

Trial Conducted at PP yard Bhilai

Annexure –V-B

 

[ As per CAMTECH Report No. CAMTECH/2008/M/W/Infra/1.0 Jan-2008 ]

(A trial was conducted at Bhilai yard to see total time taken from placement to ready per train )

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

	Detaching diesel engines, creation of air pressure, continuity test, issue of BPC and dispatch of train ( 45 minutes)

 

Annexure V-C

The flow chart indicating the sequence of activities :

(Based on trial conducted at NKJ yard to see total time taken from placement to ready per train

 

)

 

 

 

tachable wagons ick)                          and wagons (1 hrs )	Repair on remaining wagons including pipe connection etc.(1 hours) * This activity will run in parallel to creation of gap and lifting of wagons

 

 

 

 

 

 

 

 

 

 

 

Annexure-VI-A

 

Approx. Cost break-up for proposed facilities

 

 

 

Sr. No.	Item	Approx.Cost in Rs
1.	Abrasion resistance granolithic concrete floor 22500 sq mts. inside 720 mts x 30 mts shed.	1.7 Cr.
2.	Shed 720 mts x 30 mts @ of Rs 14,500 per sq meter.	31.32 Cr.
3.	7 EOT cranes of 30 T capacity @ 0.75 Cr.	5.25 Cr.
4.	Shed illumination and power supply	2 Cr.
5.	Yard alteration	2 Cr.
6.	Sick line extension and upgradation	2.5 Cr.
7.	Other M&P	2 Cr.
	TOTAL	46.77 Cr.

 

2 R & D lines and 720 mts x 30 mts shed complex will be sufficient for examination upto 10 rakes per day on an average.

 

 

 

 

Present scenario                    ( for 10 rakes/day examination)

1. Average detention per rake =

17.10 hrs.*

171. Total rake hrs spent from arrival to departure =171.40 hrs
172. Rake days locked in yard (171.4/24) = 15 Future scenario
173. Detention per rake = 5
174. Total rake hrs spent on account of examination= 50 hrs (Arrival to departure)
175. Rake days locked in yard (50/24) = 08

Monetary Savings (In terms of cost of wagon)

D.           Cost of wagon                                                   =  18.5 lacs

18. Cost of one rake = 58×18.5                       = 1073 lacs

NET SAVING OF RAKES WILL BE 7.15-2.08 = 5.07 RAKES PER DAY

Savings in terms of rake cost = 5.07×1073              = 5440 lacs

= 54.40 Crores

(monetary saving)

1. The net earnings (excluding haulage costs) per wagon hour is Rs.316/-

Net annual additional earnings due to recommended pattern

= Earning/wagon x No. of wagons per rake x no. of hours/year

= 316 x 58 x 365 x 24

= 16.05 Crores

Hence net annual savings due to proposed facilities

= Net saving of rakes x net earning per rake-Addl operating cost

= Rs.(5.07 x 16.05 ) – 1.43

= Rs. 79.95 Crores

 

 

 

(for existing efficient yards)

Present scenario        ( for 10 rakes examination per day)

1. Average detention per rake =

9.30 hrs.

1. Total rake hrs spent from arrival to departure = 93 hrs
2. Rake days locked in yard (93/24) = 875 Future scenario
3. Detention per rake = 5
4. Total rake hrs spent on examination ( AR_DP)= 50 hrs
5. Rake days locked in yard (60/24) = 08

 

 

NET SAVING OF RAKES WILL BE 3.875 – 2.08 = 1.795 RAKES PER DAY

Monetary Savings (In terms of cost of wagon)

18. Cost of wagon =  5 lacs
19. Cost of one rake = 58×18.5                       = 1073 lacs

Savings in terms of rake cost = 1.795×1073               = 1926 lacs

= 19.26 Crores

 

 

Net earnings per rake

= 16.05 Crores

 

 

Hence net annual savings due to proposed facilities

= Net saving of rakes x net earning per rake – Addl.operating cost

= Rs.(1.795 x 16.05 ) – 1.43

= Rs. 27.37 Crores

 

 

 

Annexure-VI-B

Savings and advantages of the proposed                                                       facilities for a model yard handling 10 rakes per day

[ As per CAMTECH Report No. CAMTECH/2008/M/W/Infra/1.0 Jan-2008 ] Present scenario

1. of rakes examined per day = 10
2. Average detention per rake = 17.10 * (* all India average based on sample figures of Oct.07)
3. Total rake hrs spent from arrival to departure =171.40 hrs
4. Rake days locked in yard (171.4/24) = 15

 

Future scenario

1. Rake examined per day = 10
2. Detention per rake = 5
3. Total rake hrs spent on account of examination= 50 hrs (Arrival to departure)
4. Rake days locked in yard (60/24) = 2.08

 

Note : 1. There will be no change in detachment due to ROH/POH.

2. There will be increase in detachment due to sick marking. But most of these sick wagons will be made fit much faster in the new system due to their attention under better working conditions and faster placement in sick-lines. There will be no increase in wagon hrs. lost in main sick line.

Net Saving of rakes will be 7.15- 2.5 = 4.65 rakes per day.

Monetary Savings

1. As per Traffic Accounts figures of SC Rly., the net earnings (excluding haulage costs) per wagon hour is 316/-.

Hence net annual additional earnings per rake saved due to recommended pattern

= Earning/wagon x No. of wagons per rake x no. of hours/year

= 316 x 58 x 365 x 24

= 16.05 Crores

 

 

 

Hence net annual savings due to proposed facilities

= Net saving of rakes x net earning per rake

= Rs.(4.65 x 16.05 )

= Rs. 74.63 Crores

 

 

1. Shunting in yard will be reduced with resultant saving in manpower and rake

• Productivity of C&W staff will improve, as they will work under covered shed with full illumination round the clock, all seasons in a year.

Average earning capacity of wagon (Traffic Costing Cell, SC Rly.)
S.No.	Details	BCN	BOXN
1	Avg. Wagon Km per Wagon day on line. (ASS-24 of 2003-04).	229.6	229.6
2	Avg. Wagon Km per one hr. (item (I) 24)	9.57	9.57
3	Carrying Capacity of Wagon in Tonnes.	55.7	58.81
4	NTKMs for one hour. (Item 2*item 3)	532.66	562.62
5	Commodity for loading	Cemt.fert.	Coal & I/ore
6	Avg. earnings per NTKM in Paise. (ASS.13 of 203- 04)	82.1	72.4
7	Earning for NTKMs Lost (Item 4*item 6) per hr.	437	407
8	Cost of haulage per WKM. (ASS.15 of 2003-04)in paise.	540.74	540.74
9	Cost of hauling a wagon per Hr.	129	129
10	Dependent Cost @78.5%.	102	102
11	Net earning/opportunity Cost per Hr. (per wagon) (item 7-item10)	336	306
12	Net earning/opportunity Cost per Hr.escalated to 2004-05. Rs.	349	316

 

 

 

Annexure-VII

 

 

Specification of Abrasion Resistance Granolithic Concrete flooring

 

ITEM-I

 

50 mm thick abrasion resistance granolithic concrete floor topping 1:1:2 (cement. fine aggregate, coarse aggregate as per ISI 5491 laid monolithically or separately on hardened base concrete metallic materials for high abrasion resistance in the top 15 thick layer only.

Without in any way restricting of modifying the provision of the general condition of contract in that regard the rates for the above items of work shall be inclusive of all costs of the following elements.

1. The work of granolithic concrete floor topping 1:1:2 (cement. fine coarse aggregate) will be carried out as per the relevant I.S. Codes, Railway’s specification of material and specification as applicable for plain, cement concrete, RCC. In addition to this the IS Code 2571 of 1970 and 5491 (latest) will also be referred for guidance.
2. The bays/floor panels layout for complete floor area will be drawn with correct level and size as per the direction of Engineer-In charge. The screed strips will be provided for granolithic as well as for base floor with all material/arrangements to ensure smooth joints/corner of
   • Providing all shuttering, centering; staging, screed plates, as require for the execution of the
   • Mixing, transporting, lifting, placing, vibrating and testing of concrete in all conditions, location and conforming to the relevant standard specification/ or IS specification as
   • All lead including crossing of roads, trenches, culvert, pipe line or any other existing feature at work
   • All costs of contractor’s labour, material consumables to plant and machineries etc. complete in all respect including compaction

 

 

 

equipment/surface vibrator for execution of work. .

 

 

 

3. The wooden float will be used to render the surface even and in level. The surface shall be tested with a straightedge and mason’s spirit level to detect any undulation in the

• The size of panels, location of expansion/contraction joint will be pre decided/finalized and work will be carried out in a planned manner and procedure as approved by Engineer in-charge /representative.

5. The concrete mix of 1:1:2 as specified in item for ingredients will be taken as 1 cement, 1 fine aggregate and 2 part of coarse aggregate by volume. The cement content for 50 mm thick granolithic concrete for 1 m² of area will be 0.56 bags (i.e.11.2 bags of cement for one m³ of concrete). The water cement ratio will be within 0.4.
6. The granolithic layer will be laid monolithically within 2 to 3 hours of laying of base concrete preferable within half an hour. The sequence of casting of granolithic layer will be monitored with care full supervision under the guidance of Engineer incharge/representative.
7. No concreting will be allowed without complete preparation of base concrete, the surface of base concrete below granolithic be kept rough to have adequate
8. The item rate includes testing of all materials as per relevant IS code specification and concrete cubes testing for concrete. The required equipment for field tests and arrangements shall be made as per direction of Engineer in

ITEM -II

 

Providing and laying 20 mm thick granolithic concrete floor topping with M35/10 immediately after casting base concrete.

Without in any way restricting of modifying the provision of the general condition of contract in that regard the rates for the above items of work shall be inclusive of all costs of the following elements.

 

 

 

• Formulating a design mix of the required strength in the number specified in the relevant standard specification and/or IS specification as
• Providing all shuttering, centering, staging, screed plates, as require for the execution of the
• Providing and fixing to correct line level, size and shape, shuttering of steel plates welded on steel framed panels and or approved quality ply wood panels fixed with counter sunk screws on steel/wooden framed panes of a design, material and construction to the satisfaction and acceptance of the Engineer or his representative. The fixing of shuttering/screed plates being done in a manner to obtain leak proof joints in the panels to prevent slurry leakage during placing or compacting of the concrete by Vibration or trawling the
• Mixing, transporting, lifting, placing, vibrating and testing of concrete in all conditions, location and conforming to the relevant standard specification / or IS specification as appropriate Including testing of material for concrete and concrete cubes.
• All lead including crossing of roads, trenches, culvert, pipe line or any other existing feature at work
• All costs of contractor’s labour, materials, consumables to plant and machineries etc. complete in all respect for execution of
• The rates are inclusive of provision of all type of joints expansion, contraction & construction joints. The dowel bars as per requirement will be paid under separate steel items. The other work and material required to provide joints, cutter, binding, placing and provision of specified joint in inclusive as approved by Engineer In
• The arrangement for adequate curing of concrete as required and directed by Engineer in charge/ representative will be made. Any deficiency in curing will result the rejection of work and full recovery for any deficiency noted during work or afterwards. The deficient level, finishing or poor compaction will result full rejection of deficient panel of flooring.

 

 

Annexure-VIII

 

 

 

 

 

Annexure-VIII-A LIGHTING ARRANGEMENT FOR CC RAKE EXAMINATION YARDS

1. OVERHEAD LIGHTING

For lighting over general shed area Illumination required        :      100 – 150 lux

Mounting                          :      Overhead hanging from covered shed structure

 

BLENDING OF LIGHTS

 

Metal Halide + blending with alternate fitting of T-5 tube light in each row (For quick recovery of lights after power failure)

 

SPECIFICATION FOR 400W METAL HALIDE LIGHT FITTING:

 

Specification for light fitting luminaire shall be as given below:

 

Voltage                          :        230V AC 1f, 50Hz

Lamp                              :        400 watts Metal Halide Lamp

Lamp type                      :        Single ended clear elliptical Metal Halide lamp Lamp base             :        E – 40.

Luminaire                       :        Integral side mounted high bay luminaire Lamp holder base    :         GES(E40), skirted porcelain.

Reflector                        :        Electrochemically brightened, high purity anodized

aluminium parabolic reflector.

Control gear                   :        Heavy duty copper wound ballast, ignitor, and power factor

correction capacitor suitable for 400 watt metal halide lamp. The control gear cover shall be swung open for easy maintenance.

Earthing terminal           :        Suitable for 14 SWG earthing wire.

Mains connector             :        2 way 10 amps G.F.P. mains connector suitable for 4 sq. mm

incoming cable.

Installation                     :        18 mm ID Eye bolt with adjustable mounting plate for well

aligned suspension.

Wiring                            :        All accessories of luminaire shall be prewired up to terminal

 

 

 

block.

Tightness level               :        For control gear compartment IP 43. IS                             :        Luminaire shall confirm IS: 10322.

 

SPECIFICATION FOR LIGHT FITTING (for 4 x 54 W T-5 Highbay

Fittings):

 

Voltage                          :        230V AC 1f, 50Hz

Lamp                              :        54 Watt x 4, T-5 energy efficient fluorescent Lamps

 

Energy Efficient High bay fitting made of Aluminium body, consisting with 4 Nos. separate Electronic ballast operative in 130V. 300V THD less than 10% having power factor more than 0.95, suitable for 4 x 54W T-5 lamps system complete with lamp, provided with suitable hanging arrangement at 12 mtr. height.

 

Dimension    : 600 x 1200 x 100 (Alternate to 400W MH lamps)

 

 

LIGHT FITTING CONFIGURATION

(Refer Drg. No. IRCAMTECH.GWL.EL.Wagon yard 1)

 

 

• Overhead light fittings should be located at the roof structure of the shed between examination lines.
• Distance between the two fittings in a row along the shed length shall be 12.0
• Light fittings configuration between two rows shall be planned in zigzag manner as shown in Drg. No.IRCAMTECH.GWL.EL.Wagon yard-1.

 

SUPPLY AND CONTROL ARRANGEMENT

Overhead 3-phase 4-wire system laid with suitable brackets and insulators along the shed structure under the roof.

Wiring:

3-phase 4-wire system, single core cable of suitable size PVC insulated 650/ 1100 V aluminium conductor, unsheathed, unarmoured confirming to IS: 1554

 

 

 

(Part I). Wiring shall run on suitable brackets mounted on shed structure with reel insulators.

Overhead 4 wire, wiring shall be connected through a suitable size 3.5 core 650/ 1100V aluminium conductor, PVC insulated and sheathed, armoured cable confirming to IS: 1554 (Part I) from MCBs. This cable should be supported on suitable wooden brackets fitted on sheds coloumn structures.

 

Switch Gears:

Each row of light fittings should be supplied through a suitable rating. TPIC switch and individual phase should be controlled by a suitable rating single pole MCB.

 

 

 

Annexure-VIII-B

 

 

 

 

Annexure-VIII-C

 

 

 

 

Annexure-VIII-D

 

Proposed Welding Transformer (Portable)

 

Transweld 202 or latest

 

 

A 220V Single Phase Welding Transformer suitable for 2.5 mm, 3.15 mm & 4.00 mm electrodes, yet ultimately portable – Transweld

202. It simply means that you get the value for your money at the instant of buying the machine itself. With ESAB’s expertise and assurance, the confidence and quality of performance comes packed with the machine.

 

 

 

 

 

Features

• 220V, portable and compact welding transformer
• 5 mm, 3.15 mm & 4.00 mm electrodes can be used
• Infinitely variable hand welding current setting
• Protection against overloading
• Manufactured in an ISO 9001 certified factory
• Class “H” Insulation

 

Description	Transweld 202
Input Voltage	220V, 50 Hz, 1 Phase
Welding Current Range	60 – 200 Amps
Dimension (L x W x H) mm	495 x 345 x 410
Weight	43 Kgs

 

 

 

Annexure-VIII-E

Proposed Welding Transformer

 

Transweld 400 – Air cooled welding transformer or latest

 

 

ESAB Transweld 400 is a 400 Amp Manual Arc Welding Transformer that combines unique functional and safety features. Ensures excellent welding quality with economy. Its natural air-cooled ensures non-stop performance even in the most uncertain difficult conditions. Ideal for use at site or in a workshop.

 

 

 

Special Features

 

• Natural air cooled machine ensures maximum safety
• Current available in single range. Current indicator and current control handle both on front panel
• Robust and compact construction ability to withstand rough handling at sites
• Horizontal shunt core travel ensures precise setting after prolonged use
• Class ‘H’ insulation provides longer coil life

 

Technical Specifications
Input
Supply Voltage	415V, 2 Lines of 3 Phases, 50Hz AC
Rated Input Current	63 Amps
Rated Input KVA	26 KVA
Output
Open Circuit Voltage (Maximum)	80 V
Range of Welding Current	80 – 400 Amps
Maximum Continuous Hand Welding current at 60% duty cycle (Rated welding current)	300 Amps
Type of welding current regulation	Stepless
Type of cooling	Natural Air Cooled
Net Weight (Approx).	115 Kgs
Approx. Dimension	600 x 410 x 720 mm

 

 

 

 

 

MULTI – UTILITY VEHICLE

Annexure-IX

 

Standardization of Infrastructural facilities for CC Rake Mainten

 

 

 

 

 

Annexure X

 

CHECK LIST FOR CC FREIGHT EXAMINATION POINT

 

Railway :……………Type of stock : …………Type of attention : … … … Division : ………….. Avg. no. of rakes examined: …………

 

Sl. No.	Item	Availability		Remarks
		Yes	No
1.	7.5 m center to center distance between two lines
2.	Concrete path way
3.	Paved road for truck movement.
4.	Supervisors Room
5.	Staff room
6.	Rolling in/out huts
7.	Field store + Tool room
8.	Compressor Room
9.	Exhauster room
10.	Battery charging room
11.	Tower light
12.	Street light along examination lines at two levels
13.	Portable rechargeable light
14.	Hand lamps
15.	Welding line
16.	Arc welding set (Mounted on trolley)
17.	Portable DG set
18.	DG set 250 KVA (for compressor, light & welding)
19.	Electric Compressor (500 CFM)
20.	Diesel Compressor (500 CFM)
21.	Gas cutting set
22.	Hyd. Cold cutting set/ Hand shears
23.	Protective clothing with Helmet & Gloves
24.	Welding Apron & welding glass
25.	Pneumatic pipe line (32mm dia.)
26.	Rake Test Rig
27.	Hydraulic Jacks
28.	Wheel Barrow
29.	Pick up van
30.	Truck
31.	Lister truck
32.	Road mobile crane

 

 

 

Sl. No.	Item	Availability		Remarks
		Yes	No
33.	Hand trolley
34.	Portable drill machine 12 mm
35.	Drill machine
36.	Bending Machine
37.	Fitter tool box
38.	Pressure gauge test stand
39.	Folding     type     portable     wheel diameter gauge
40.	Wheel distance measuring gauge
41.	CBC height gauge
42.	Tyre defect gauge
43.	Electronic      device/      Infra     red thermometer for detecting warm box
44.	Electric operated hand tools i.e. Grinder.
45.	Pocket Jack (Hydraulic) 6 Tons capacity.
46.	Hand tools
47.	Storage rack with pigeon holes
48.	Rack with Locker
49.	Fax machine with P&T line
50.	Walkie Talkie set/ Mobile phone
51.	Railway Telephone
52.	BSNL Telephone
53.	Computer with printer, Scanner, UPS with preloaded software & modem
54.	C&W Office furniture
55.	Railnet / Internet connection
56.	Zerox Machine
57.	First aid equipment

 

 

 

 

CHECK LIST FOR SICKLINE OF EXAMINATION YARD

 

Railway :……………Type of stock : …………Type of attention : … … … Division : ………….. Avg. no. of coaches attended : …………

 

Sl. No.	Item	Availability		Remarks
		Yes	No
1.	Covered Shed
2.	SAB Repair Room
3.	DV Test Room
4.	Service Building
5.	Computer Room
6.	Store Room + Sub store
7.	Machine Shop
8.	Battery room for charging lister/ jumbo truck batteries
9.	Compressor Room
10.	SE/JE Room
11.	Pit line
12.	EOT Cranes 15t/ 5t
13.	EOT Crane 10T / 3T
14.	Road Crane 10T Capacity
15.	Jib Crane 2.5T
16.	Electrical    Stationary    Screw    Air Compressor    With    Air    Receiver (500CFM)/ Dsl compressor
17.	Turn Table
18.	Trestles
19.	Hydraulic Pipe Bending Machine
20.	Bench Drilling Machine
21.	Heavy     Duty    Pedestal     Grinder Double Ended
22.	Shearing Machine 6 mm x 2200 mm wide
23.	Battery Charger
24.	Weighing Machine 500 Kgs.(for scrap disposal )
25.	DG Set
26.	Gas Cutting Equipment
27.	Plasma Arc cutting machine for SS wagons
28.	Work Station for Bogie Repair
29.	Welding Machines
30.	MIG/TIG welding machine for SS wagons
31.	Winches
32.	Bogie Manipulators

 

 

 

Sl. No.	Item	Availability		Remarks
		Yes	No
33.	Pipe line for air 32 mm diameter
34.	CO2 Welding Machine
35.	Rail cum road vehicle
36.	Fork Lifter 3 Ton
37.	Truck 10 Ton Capacity
38.	Tractor    With    Hydraulic    Lifting Machine & 3 Trolleys (Trailers)
39.	Platform Truck 2 Ton
40.	Light Store Vehicle
41.	Hand Trolleys with Rubber Wheels
42.	Water Cooler
43.	Floor cleaning machine
44.	Fitters Lockers
45.	Fax With P&T Line
46.	First Aid Equipment
47.	Photocopier
48.	VHF Sets/ Mobile phones
49.	Storage Racks
50.	Portable Hydraulic Riveter
51.	Stores Bin
52.	Portable Electric Grinders
53.	CBC & Draft Gear Replacement Equipment
54.	SAB Test Bench
55.	Hydraulic Jacks 15 Ton
56.	Set of special spring spanners, Box spanners, Torque spanners
57.	Bottle jacks
58.	Pneumatic/ Electrical hand tools
59.	Gauges & Instruments
60.	Single Wagon Test Rig
61.	DV Test Stand
62.	Hand Tools
63.	Pneumatic Torque Wrench With Sockets 1″ to 2″
64.	Ultrasonic leak detector for tank wagons)
65.	Pressure gauge dead weight tester

 

CAMTECH/2017/M/CC-INF-STD/1.0                                                                                                                          53

Annexure XI

RECOMMENDED ILLUMINATION AS PER IS 3646 (PART 1): 1992

 

SL No.	Type of work	Relevant Clause of specification	Recommende d Illumination	Quality Class of Direct Glare Limitation	Remarks
1.	Goods Yard	Adapted from Clause 23.8.1.5	5-20	–	The level may depend on topography, road conditions, drainage, vegetation, shunting frequency and yard capacity.
2.	Entrance of Yard for Rolling –in-Examination	Adapted from Clause 7.7.1	300-500-700	1	As moving parts are examined, values nearer upper limit should be selected.
3.	Vacuum Exhauster/Air Compressor Room	Adapted from Clause 23.7.1.5	100-150-200	2
4.	Store	Adapted from Clause 16.1	100-150-200	3
5.	Wagon body lifting Shed	7.6.2	300-500-750	2	As moving parts are examined, values nearer upper limit should be selected.
6.	Machine Shop	7.3.2	300-500-750	2
7.	Reclaim Section	7.3.1	200-300-500	3
8.	Test Lab (D.V., SAB, Hydraulic Jack etc.)	7.6.3	500-750-1000	1
9.	Wheel shop (i)                   General (ii)                 On Wheel Lathe	7.1.1 7.3.3	200-300-500 500-750-1000	3 2	Local    lighting    may    be    used             to supplement the general lighting in wheel lathe area.

NOTES

 

1. The above values are based on the IS Specification listed above, which may be referred for further
2. The number and quantity as well of type of bulbs may be decided based on the values for recommended illumination and quality class of direct glare limitation.
3. These values are indicative and may need to be reviewed to suit local conditions

 

Suggestions received during Seminar at CAMTECH on 28.04.2017

SN	Suggestions	Suggested by	Remarks by RLy Board
01	Rake ID should be mentioned in revised BPC formats.	STA/WCR, NKJ
02	Kilometres logging in BPC is not being done by crew. Validity should be decided as per no. of days only.	HPT/SWR, SMP/WR, NJP/NFR STA/WCR
03	BOXN-HL wagon pillar are getting off from bottom and wagon body is expanding.	HPT/SWR, NKJ/WCR
04	Cases of Door eye bolt broken in BOXN-HL wagon is more.	HPT/SWR, NKJ/WCR
05	Space for 11 digit wagon number is insufficient in BPC .	SDAH/ER, SMP/WR, STA/WCR
06	BPC Format should be bilingual.	SDAH/ER, SMP/WR, STA/WCR
07	Striker casting may be condition basis in place of must change in ROH.	SDAH/ER, MGS/ECR, BSP/SECR, Gooty/SCR
08	Vertical liner for flat type centre pivot should be must change in POH	MGS/ER
09	Clearance between pins and bushes (not more than 1.5 mm) is difficult to check during maintenance in sick line. (given in table 2.3 item 3.0 Bogie brake gear of Revised maintenance manual for wagons)	NKJ/WCR SMP/WR, STA/WCR
10	Gradients for train examination yard should be specified.	NKJ/WCR SMP/WR, STA/WCR
12	Standard Specifications/drawings for Bogie manipulator, wheel turn table, Bogie assembly line carrier and mobile work station required.	SMP/WR STA/WCR
14	No. of revalidation of CC rake and validity of revalidation to be specified.	ADI/WR SMP/WR STA/WCR
15	Railnet should be provided in all examination yards.	ADI/WR SMP/WR STA/WCR
16	Concept of CC rake formation from off ROH/POH wagons may be elaborated.	GIM/WR SMP/WR STA/WCR
17	In service safety tolerances should be provided, some accidents cases findings are pending due to non availability of safety tolerances in line with P-Way.	SC/SCR SMP/WR STA/WCR

 

SN	Suggestions	Suggested by	Remarks by RLy Board
18	Tolerances should be provided for trammelling gauge dimensions & other bogie dimensions.	RDM/SCR, BZA/SCR
20	Length of pit line for ROH repair need to be increased for better examination of under gear parts.	RDM/SCR
21	CC rakes are running after expiry of BPC validity by traffic. It should be avoided.	KJGY/NR SMP/WR STA/WCR
22	Mostly BOXN wagons body and doors are being damaged during loading/unloading.	NGY/NFR SMP/WR STA/WCR
23	Instruction for maintenance of bogies with LSD and BMBS are required in field.	Gooty/SCR SMP/WR STA/WCR
24	Standardization for measuring heights of springs (grouping) with the help of machine should be done.	Gooty/SCR, BZA/SCR SMP/WR STA/WCR
25	LED inspection lamp is better for examination.	MGS/ECR, NKJ/WCR SMP/WR STA/WCR
26	Both Diesel & Elect. Compressors are required in CC Rake depot.	NKJ/WCR & SMP/WR
27	LED hand held rechargeable torch is required for CC rake examination	MGS/ECR, GIM/WR
28	Covered shed is not required for examination lines.	SMP/WR STA/WCR
29	6 Nos. tower lights/high masts required for 750 m length examination line.	MGS/ER, NKJ/WCR & KGJY/NR
30	One dedicated shunting Loco is required (under control of operating Deptt.)	NKJ/WCR & KGJY/NR SMP/WR STA/WCR
31	For rake testing, taping from air pressure line is required at starting end and air pressure line is required at only one line and taping to be provided for other lines.	NKJ/WCR & KGJY/NR SMP/WR STA/WCR
32	Total 03 Nos. welding plants are required one for each line and two spare plants for breakdown.	MGS/ECR & GIM/WR
33	01 no. MUV (multi utility vehicle)/yard is required for material transportation.	NKJ/WCR, SMP/WR STA/WCR
34	01 no. staff van/yard is required for staff transportation.	NKJ/WCR, MGS/ECR SMP/WR STA/WCR

 

 

SN	Suggestions	Suggested by	Remarks by RLy Board
35	01 no. Pickup van/yard is required for Depot.	RTM/WR & BSP/SECR SMP/WR STA/WCR
36	02 Nos. of truck also required for transportation of store material.	SMP/WR & MGS/ECR SMP/WR STA/WCR
37	01 Road mobile crane of 15 T capacity is required in depot.	MGS/ECR SMP/WR STA/WCR
38	Portable drill machine and hand grinder are required	MGS/ECR & STA/WCR SMP/WR
39	Pit is required for maintenance of wagon fitted with BMBS and BVZI brake van & Tank wagon.	MGS/ECR & BIA/SECR SMP/WR STA/WCR
40	WARS (Software for freight Depot) to be developed in new version to meet present requirement.	MGS/ECR & STA/WCR SMP/WR
41	No. of Hand trolley in depot may be decided as per requirement of individual depot.	KGJY/NR & SMP/WR STA/WCR
42	OHE lines should not be provided over maintenance lines but in many depots, OHE lines are available over maintenance lines. There must be a isolation facility to isolate OHE lines.	VSKP/ECoR & NJP/NFR SMP/WR STA/WCR

 

 

 

 

 

 

 

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