Draft Guidelines On Maintenance Facilities in Coaching Depots On IR

(For official use only)
Government of India
Ministry of Railways
Draft Guidelines for

Maintenance Facilities
In
Coaching Depot on IR
CAMTECH/M/GWL/MFCD/1.0
November 2014
Draft Guidelines for
Maintenance Facilities
In
Coaching Depot on IR
Preface
Railway Board has issued instructions vide letter No. 2007/MC/141/1 dated
12.03.14 to CAMTECH to prepare Pre-fabricated pit line for coaching depots to
facilitate maintenance staff in doing faster and quality maintenance schedule & to
minimise maintenance cost also. During meeting for “Review of IOH/ POH
periodicity of coaches and performance review of LHB coaches” held in Railway
Board on 06.03.2014, it is decided that hand book should be prepared according to
requirement in line with DMRC and revision in M&Ps should also be done to have
full complement of tools/equipments & other machine plants in coaching depots.
These guidelines are prepared with the objective to provide informative technical
details on “Pre-Fabricated pit line without catwalk with coach washing plant” for
the guidance of Mechanical engineers involved in maintenance of Coaching stock.
It covers the constructional features of fabricated pit line, lay out drawing of pit line
without cat walk & with Automatic coach washing plant.
This Hand book does not supersede any existing instructions from Railway Board,
RDSO & Zonal Railways and the provisions of IRWM, BIS codes & reports on the
subject. This Hand Book is not statutory and contents are only for the purpose of
guidance. Most of the data & information mentioned herein are available in DMRC
and Coaching Depots on IR.
We welcome any suggestions from our readers for further improvement.
CAMTECH/Gwalior (K.P.Yadav)
Date : 25.11.2014 Director/Mech.
Contents
S.N Description Page no.
1.0 Objectives 1
New design of pre-fabricated pit line without catwalk and 1
2.0
with ACWP (Automatic Coach Washing Plant)
2.1 Merits and Demerits of catwalk 2
2.2 Covered Shed 3
2.3 Views of Railways considered for provision of catwalk 3
3.0 Twin depth pit line 4
4.0 Modern equipments 4
5.0 Other facilities 4
6.0 Coaching Depot Layout 4
7.0 Data/details of layout of coaching complex 6
8.0 Features of maintenance bay 8
Features of maintenance bay 9
9.0
(pit line without catwalk with shed)
Features of maintenance bay 10
10.0
(pit line without catwalk without shed)
11.0 A view of pit line at DMRC on steel pillars: 12
12.0 Maintenance bay showing ramp, stairs & pillars: 13
13.0 Service room & space for vehicle & machinery: 14
14.0 Features of IOH depot (maintenance sick line): 15
15.0 Maintenance sick-line 16
Details of infrastructure facilities proposed for 17
16.0 primary maintenance depot holding 500 coaches (100 AC +
400 Non AC)
17.0 Some modern equipments 26
18.0 Automated Wheel Diagnostic System (WDS) 26
19.0 Mobile lifting platform 30
20.0 Coach lifting system 31
21.0 Wheel changing system 32
22.0 Mechanised Laundry for Linen washing 33
23.0 Automatic Coach washing system (ACWP) 40
24.0 Layout and construction of automatic coach washing plant 42
25.0 Process of coach cleaning and washing in different stages 45
26.0 Internal coach cleaning machine 49
27.0 Justification of ACWP for coaching depots 50
28.0 Justification of coach lifting plant for coaching depots 51
29.0 Covered shed 51
30.0 Justification for all weather shed for coaching depots 52
31.0 Proposed lighting solution of coaching depots 54
32.0 Additional/Optional provisions 62
Suggestions given by zonal railways for prefab pit line and 69
33.0
coaching depot infrastructure during seminars.
ISSUE OF CORRECTION SLIPS
The correction slips to be issued in future for this handbook will be

numbered as follows:
CAMTECH/2014/C/FOUNDATION/1.0/CS. # XX date ...………….......
Where “XX” is the serial number of the concerned correction slip

(starting from 01 onwards).
CORRECTION SLIPS ISSUED
Sr. No. of Date of Page no. and Item No. Remarks

C.Slip issue modified
CAMTECH/2014/M/MFCD/1.0 1
1.0 OBJECTIVES:
Railway Board vide their minutes of the meeting for “Review of IOH/ POH
periodicity of coaches and performance review of LHB coaches” held in
Railway Board on 06.03.2014, No. 2007/M©/141/1 dated 12.03.14 under
item “B” and S. No. 14 for performance review of LHB coaches and other
issues directed CAMTECH to evolve a design of pit line with pre-fab.
constructions for expeditious implementation of projects. In addition to this,
need to construct a catwalk should also be re-examined as pit lines without
catwalks also have advantages of more open space, easy and speedy
construction and are economical as well. This hand book is prepared to cater
all the requirements of coaching depots.
2.0 NEW DESIGN OF PRE-FABRICATED PITLINE WITHOUT

CATWALK AND WITH ACWP (AUTOMATIC COACH WASHING
PLANT
Previously a 3Tier system for coach maintenance was adopted by Indian
Railway on the basis of recommendations made by CAMTECH and
approved by Railway Board vide their letter No. 95/M©/165/11 dated
09.08.1999. In three tier system, the provision of catwalk was made for
washing/ cleaning operation of coaches during maintenance. During
finalisation of report, the provision of automatic coach washing plants at
maintenance depot was examined but, at that time, Indian Railways were
still in the process of laying these plants at few locations. It was decided
that as Railways as become fully confident with their design, performance
and sources of supply and automatic plants get proven in service, the above
arrangement may be reviewed suitably in order to explore the possibility of
having pit lines without catwalks.
In catwalk less design, for changing destination boards and window glass
cleaning, adequate number of movable trolleys/forklifts with suitable
attachment may be required. The requirement of water pipeline for coach
washing may also be reviewed in such cases.
As discussed in 12th CMG at Guwahati & CME‟s conference at Mumbai

and Shimla, it is felt by some of the Railways that the activities to be carried
out on a catwalk can be undertaken with the help of alternative means such
as mobile platforms, listers etc and therefore pit line design should be
without cat walk.
During the seminar at CAMTECH on 21.07.2014 on the issue, participants

were of the opinion that catwalk contributes little but only makes hindrance
in the free movement of man and material. Daylight is restricted and layout
Hand Book on maintenance facilities in coaching depot on IR November - 2014

makes clumsy. A new design of pit line without catwalk should, therefore,
be developed or Prefab casted catwalk with longer span may be provided.
Automated Coach Washing Plant
ACWP has been considered necessary for outside cleaning of the coaches.
This will reduce the efforts and time taken at the pitline considerably. It
will also improve the quality of the cleaning of the coaches. This will
ensure reduction in water consumption and wetness in the pitline. It has
been noticed that coach washing plants which are in use on Indian Railways
are not working properly due to various reasons. It is, therefore, proposed
that a washing plant of a specification equivalent to one available at
DMRC/PA coaching depots should be provided.
Unified Maintenance Pit-line
A unified pitline for internal cleaning of coaches/examination and repair has

been considered in place of separate facilities for internal cleaning of
coaches and repair/examination of coaches. It has been noticed that if
separate facilities are provided, the time taken in shunting is 1-2 hours and
thus the cycle time increases considerably. The very purpose of this
exercise i.e. to reduce the maintenance time gets defeated. Further, since
ACWP has been provided, the coach washing will anyway be done at the
entry point of the pitline, therefore, spillage of water on pitline will be
reduced to a great extent. This will serve the purpose of keeping the pit dry
to a great extent.
2.1 Merits and Demerits of Catwalk
SN Disadvantages of Catwalk Advantages of without Catwalk

01 Clumsy lay out Less clumsy lay out
02 Day Light is restricted Plenty of daylight id available
03 Cross movement is also Easy movement of maintenance
restricted staff

2.2 Covered Shed
The coaching stock examination pattern in recent years has been changed
considerably resulting into extensive utilization of coaches. A rake once
turned out from a pit line will be examined after 3500 Kms and on round
trip basis, there can not be any compromise on quality of examination and
repairs. Extreme weather conditions like heavy rains etc will make it
difficult for the staff to do a quality job in time provided for examination.
Therefore a all weather covered shed has been provided. This will ensure
proper working conditions to the staff throughout the year and will save the
staff and the stock from the vagaries of weather. In this respect comparison
was made with the existing design of structure vis-à-vis pre-engineered
buildings. It has been noticed that the pre-engineered buildings have
following features:-
 Simple design and light foundations

 Standard component connections
 Short learning curves
 Fast and standardized erection process
 Low weight flexible frames offer higher resistance to seismic forces
 Future expansion is simple, easy and cost effective
 Lighter structure weight
The cost of pre-engineered buildings is also less in compared to conventional

design buildings, therefore pre-engineered buildings have been recommended.
2.3 Views of Railways have been considered for provision of catwalks.
Railways are sharply divided on view of this facility. While E.Rly,

S.E.Rly. strictly feels that a catwalk is must, W.Rly. and C.Rly. are of the opinion
that catwalk is not required and work can be managed with portable lifting
platform. Views of other railways were also taken.
One more design has also been evolved by CAMTECH where catwalk can be
provided only at one side of the each pit and central bay can be left for movement
of the lifting platform.
As discussed in 12th CMG at Guwahati & CME‟s conference at Mumbai and

Shimla, it is felt by some of the Railways that the activities to be carried out on a
catwalk can be undertaken with the help of alternative means such as mobile
platforms, listers etc and therefore pit line design should be without cat walk.
However some other Railways were of the view that these activities can not be

done properly without catwalk. The issue has been deliberated in detail. It is
proposed that Railways can have option from the two designs i.e.
i) No catwalk on either side
ii) Catwalk only on one side of pit line and area between two pit lines
should be without catwalk for free movement of man and material.
The details of these two designs are as per CAMTECH sketch no.3
and 4.
3.0 Twin depth pit
In the existing pit, staff can not walk without bending. Therefore, to avoid
this difficulty, it has been proposed to provide twin pit. In this design a pit
of size 600 mm wide and 450 mm deep pit has been provided in centre of
the main pit for easy walking of the staff. This will also serve as drain to
the pit as a FRP/Metallic mesh has been provided as a covered on the deep
drain for this purpose.
4.0 Modern Equipments
To improve reliability, reduce maintenance time and to have state of art,

facilities for examination, repair and maintenance of coaches, following
modern equipment have been recommended:-
 Automated Wheel Diagnostic System

 Mobile Lifting Platform
 Bogie/Car body lifting System
 Waste removal system for Bio-Toilets/Vacuum Toilets
 Automatic in-motion Train Washing System
 Bogie turn table.
 Bio-Toilet evacuation machine
5.0 Other Facilities
Other facilities such as boundary wall, pliable road throughout the coaching
depot, concrete flooring, service rooms, proper lighting and their accessories
have also been proposed.
6.0 Coaching Depot Layout
6.1. The coaching depot is planned for 26 coach length rake.

6.2 The coaching depot consists of

a) Automatic in-motion coach washing plant (ACWP)

b) Automated wheel diagnostic system (WDS)
c) Maintenance bay (Pit-line)
d) Maintenance Sickline (under covered shed)
e) Service rooms
f) Stabling line
g) Shunting neck
6.3 Sequence of operation
(a) Train entering into the coaching depot
(b) Outside train washing on automatic in motion coach washing plant
(c) Detection of wheel defect on automated wheel diagnostic system
(e) Placement of rake on maintenance bay for complete maintenance and

safety examination
(f) Pulling the rake in shunting neck
(g) Train going out of the coaching depot after complete maintenance
Ref: Sketch-01

7.0 Data/detail of layout of Coaching Complex
7.1 (a) Length of the Coaching Complex = 2104 m

(b) Width of the Coaching Complex = 120 m
7.2 (a) Thickness of boundary wall = 23 cm

(b) Height of boundary wall = 2 m
(c) Length of boundary wall = 4000 m
7.3 (a) Width of road = 5 m

(b) Length of road = 2285 m
7.4 (a) Total track length = 6 km

(b) Number of points and crossings = 9 sets
7.5 (a) Width of the maintenance bay = 14.49 m

(b) Length of the maintenance bay = 620 m
(c) Construction of the maintenance bay = as per drawing/detail
7.6 (a) Width of maintenance Sick line = 19.5 m

(b) Length of maintenance Sick line = 200 m
(c) Construction of maintenance Sick line = as per detail
7.7 (a) Width of Service rooms = 5m

(b) Construction of Service building = as per detail
7.8 (a) Width of compressor and exhauster rooms = 5m

(b) Length of compressor and exhauster rooms = 10 m
(c) Number of rooms = 2 nos.
7.9 (a) Width of sub-station rooms = 5 m

(b) Length of sub-station room =10 m
(c) Number of sub-station room= 2 nos
Ref: Sketch-01

CAMTECH/Gwalior
Sketch No. 1
Prepared By

8.0 Features of maintenance bay

8.1 Data/dimensions :
(a) Length of maintenance bay = 620 metres
(b) Width of maintenance bay = 14.49 metres
(c) Capacity = 2 rakes
8.2 The maintenance bay is meant for all safety checks, schedule and non
schedule maintenance of under gear and upper gear.
8.3. Main features of the maintenance bay are -

a. Broad and obstacle free pathways.
b. Under pit pathway below the rake/track.
c. Pit line on metallic (steel) pillars.
d. Ramp at both the sides to go from ground level to pathways.
e. Provision of stairs to go from ground level to pit pathway.
f. Provision of service rooms.
g. Provision of mobile lifting platform (for without catwalk).
h. Provision of compressed air pipe line.
i. Provision of overhead light.
j. Provision of under pit light.
k. Provision of 48V,110V, 230V ,440V cables and sockets
8.4 Other salient features:
a. The covered shed is having zig-zag placement of sufficient number of

transparent sheet for sufficient natural light during day time.
b. To make the pathways obstacle free cables for the sockets are running
underground.
c. The under pit light are located such that they come under each bogie
of each coach.
NB : 1. The sketch of maintenance bay does not have structural and

foundation design of load bearing items.
2. Hence the dimensions shown may require changes due to design
considerations.

9.0 Features of maintenance bay (pit-line without catwalk with shed)
9.1. Data/dimensions :
PIT LINE WITHOUT CAT-WALK
a
a
3245 3245
5m
4025
3m
b
d d d d 2m Ground Level
960 960 1300 960

1250 785
e 2500 600 3000 2500 e
325 450
250 C
400 Drain Sketch No. 2
850
Prepared by CAMTECH Gwalior
Note : The pit line is proposed on steel pillars of 500x500 size with a clear space
of 1000 mm between the pillars. The detail drawing to be prepared by the
Zonal Railways based on actual site conditions and necessity of loco
movement.

10.0 Features of maintenance bay (pit-line without catwalk without shed)
10.1. Data/dimensions :

10.2 Features of maintenance bay (pit-line with side catwalk)
1. Data/dimensions :
Covering features of both pitline with catwalk and without catwalk
Note :The pitline is proposed on steel pillars of 500x500 size with a clear space of
1000 mm between the pillars. The detail drawing to be prepared by the Zonal
Railways based on actual site conditions and necessity of loco movement.

11.0 A view of Pit line at DMRC on steel pillars:
Pit line at DMRC

12.0 Maintenance bay showing ramp, stairs & pillars:
CAMTECH/Gwalior
Sketch No. 4
Prepared By

SERVICE ROOM AND SPACE FOR VECHILES AND MACHINERIES
Maintenance Bay
CAMTECH/2014/M/MFCD/1.0
2
5 30
2
Hand Book on maintenance facilities in coaching depot on IR

5 Vehicle Space Space for service room, vehicle and machines
Examination pit Maintenance Workshop
1. The service rooms are located in between maintenance bay and maintenance workshop serving at one side to maint.bay and at other side to maint.workshop.
13.0 Service Room & Space for Vehicle & machinery:
2. All rooms are having doors,windows and racks etc of standard dimensions. Sketch No. 5
3. All rooms are fitted with standard electrical fittings of suitable and appropriate quantity and quality
4. The sketch does not have structural and foundation detail of the rooms. Prepared By
CAMTECH/Gwalior
November
14
- 2014
14.0 Features of IOH Depot (Maintenance Sick Line):
1. Data/dimensions :
(i) Length of maintenance sick line = 200 metres
(ii) Width of maintenance sick line = 19.5 metres
(iii) Capacity = 2 lines
2. The IOH Depot (maintenance sick line) is meant for attending the unfit
coaches and for attending higher maintenance schedules of the coaches.
3. Main features of the maintenance sick line are:
a. Provision of 04 coach length examination pit – one on each line.

b. Provision of wheel profile lathe.
c. Provision of bogie/coach lifting system.
d. Provision of equipments like coach lifting jacks, material carrier,
fork lifter, hoist, bogie turn table.
e. Provision of service rooms, store and vehicle parking space.
f. Provision of wheel parking.
g. Provision of covered shed.
h. Provisions of electrical fitting, light, fan etc and electric supply to all
fixed and portable machines and equipments
NB : 1) The sketch of maintenance sickline does not have structural and

foundation design of load bearing items.
2) Hence the dimensions shown may require minor changes due to
design considerations.
3) Big machineries like wheel lathe, coach lifting system etc should be
installed suitably.
Ref: Sketch No. 05 & 06

15.0 Maintenance Sick-line:
CAMTECH/Gwalior
Sketch No. 6
Prepared By

16.0 DETAILS OF INFRASTRUCTURE FACILITIES PROPOSED FOR

PRIMARY MAINTENANCE DEPOT HOLDING 500 COACHES
(100 AC + 400 NON AC)
16.1. INFRASTRUCTURE & BUILDING
S.N. ITEM COACH

HOLDING
500(100 AC +
400 NON AC)
1. Covered shed (sick line ) 1
2. Maintenance lines with pit
2x4
(No. of lines X No. of coaches)
3. Linen store room, size 5 m x 10 m 2
4. Room for storing cleaning equipment, size 5 m x 10 m 1
5. Mech. Item repair room with test benches, size 5m x 8
4
m (DV, brake cylinder, CDTS etc)
6. Mechanical millwright room, size 5 m x 8 m 1
7. Computer room, size 5 m x 5 m 1
8. Battery room with battery beds, size 5m x 10m 2
9. Fans repair room, size 5 m x 10 m 1
10. Light fittings repair room, size 5m x 10m 1
11. Alternator/ regulator repair cum testing room, size 5m
2
x 10 m
12. Compressor repair room with AC cabin, size 5m x 5m 1
13. Switch gear test room with shelves and test benches/
1
work benches, size 5 m x 8 m
14. Motors repair room with shelves and test
1
benches/work benches, size 5 m x 8 m.
15. Simulator training room for RMPU, inverter & power
1
panel, size 5 m x 10 m.
16. Filter cleaning arrangements with blower & water
1
sump size 5m x 5m
17. Tool room with shelves & almirahs, size 5 m x 8 m. 2

S.N. ITEM COACH

HOLDING
500(100 AC +
400 NON AC)
18. Storing facility for Lube, HSD, Kerosene oil, size 5m
1
x 5m.
19. Storing facility for refrigerants, DA, Oxygen, Nitrogen
1
cylinders, size 5 m x 5 m.
20. Pantry equipment repair room, size 5 m x 5 m. 1
21. Depot Officer room (Gazetted) , size 5 m x 5 m. 1
22. Incharge/ Supervisors office , size 5 m x 5 m. 4
23. Establishment office, size 5 m x 10 m 1
24. PPIO office, size 5 m x 5 m. 1
25. Material management office, size 5 m x 5 m. 1
26. Main store with Unit Exchange Spares and material
3
storing facilities size 5 m x 10 m.
27. Shift/ Custody stores with material storage facilities,
2
size 5 m x 5 m.
28. Conference room of size 5 m x 10 m. 1
29. Staff room with lockers, size 5 m x 8 m. 2
30. Staff room for ladies size 5 m x 5 m 1
31. Electronic lab (AC) with all repair and testing
1
facilities, size 5 m x 5 m
32. Staff training room facilities including Multimedia
projector, LCDTV, video camera, DVD Handycam & 1
other modern teaching aids, size 5 m x 8 m.
33. Vehicle repair room, size 5 m x 8 m. 1
34. Staff Canteen of size 5 m x 20 m. 1
35. Mechanised Laundry for linen washing on BOOT 1 Unit
model
36. Bio-Toilet Evacuation Machine 1

16.2 OTHER INFRASTRUCTURE
S.N. ITEM COACH

HOLDING
500(100 AC +
400 NON AC)
1. Scrap material space of adequate size 1
2. Scooter & cycle stand 1
3. Separate toilets for ladies & gents at suitable 4

locations
4. Garage pickup van/ material van 2
16.3 MACHINE & PLANT (Mechanical)
S.N. ITEM COACH

HOLDING
500(100 AC +
400 NON AC)
1. Automatic coach washing plant (ACWP) 1
2. Wheel diagnostic system (WDS) 1
3. Coach lifting system 1
4. Wheel profile lathe 1
5. Hydraulic lifting jack/Whiting Jacks 6
6. Welding plant (portable) Single phase 230 V 4
7. Welding plant (Stationary) 3 Ph. 440 V 2
8. Air compressor-350 cfm 2
9. EOT crane 5T in maintenance sick line 2
10. Floor scrubber 10
11. Dry & wet vacuum cleaner 10
12. Mobile jet cleaner 10
13. Drainage pump heavy duty 5HP (Muck pump
2
centrifugal)
14. Sewing machine 1
15. Portable pump 2
16. Gas welding-cutting set 4
17. Lathe machine, 1000mm between center complete 1
S.N. ITEM COACH

HOLDING
500(100 AC +
400 NON AC)
including spares and accessories with attachment
for precision grinding and tapering.
18. Bench vice 4
19. Medium sized electric motor driven pillar drilling 2
machine complete.
20. Heavy-duty motor driven pedestal grinder 2
complete.
21. Portable electric motor driven drill machine. 4
22. Portable electric motor driven grinder. 2
23. Electric motor driven Winching machine for 2
movement of coaches of suitable capacity
24. 46.7 Ltrs spare oxygen (7 m3 ) cylinders 4
25. 41 Ltrs spare Acetylene (5.5 m3 ) gas cylinders 4
26. As per
Hand tools for mechanical staff requirement
27. Maintenance staff tool boxes with tools. For each
technician
16.4 MACHINE & PLANT (Electrical)
S.N. ITEM COACH

HOLDING
500(100 AC +
400 NON AC)
1. Distilled water plant – preferably solar system, (in
2 x 100 lpd
ltrs per day)
2. Condenser cleaning tank 1
3. Hydraulic operated scissor – type platform truck of 4
1Tonne capacity.
4. Vacuum pump with gauges etc. 2
5. Battery charger sets 110V, 300A DC 3
6. Portable battery charger input 230 V single phase, 2
output 110V, 40A DC

S.N. ITEM COACH

HOLDING
500(100 AC +
400 NON AC)
7. Battery charging/ pre cooling sockets with At each coach
universal type connector length
8. Constant current constant voltage battery charger 1
upto 10 cells.
upto 12 cells
upto 56 cells.
11. Constant current discharger. 2
12. Battery analyzer 2
13. Air quality measurement facility 2
14. Dynamic balancing machine for balancing of fans, 1
shafts & alternator pulley
15. Hydraulic puller of 10T capacity 2
16. Escorting staff tool boxes with tools. (As per For each
RDSO) escorting staff
17. Maintenance staff tool boxes with tools. (As per For each
RDSO) technician
18. Motorised Megger 500, 1000V. 4
19. Refrigerant recovery plant. 1
20. Electronic weighing machine upto 15kg 2
21. Electronic weighing machine upto 50 kg 3
22. Electronic weighing machine upto 500 kg 1
23. Ordinary tool set for tool room (Torque wrenches,
special spanner, soldering iron, manual cable
crimping tool, hydraulic crimping tool, cable
15
stripper, cable cutter, pliers, screw drivers, line
tester, cell tester, test lamp, hammers, mallets,
riveting tool, punching tool)
24. Measuring tool set for tool room (dial indicators, 15
S.N. ITEM COACH

HOLDING
500(100 AC +
400 NON AC)
feeler gauge sets, vernier calipers, vernier
micrometers, torque wrench, depth gauges, screws
gauge, Go/No Go gauges, Hydrometer)
25. Special tools for AC for tool room (Refrigerant gas
leak detector, Tube cutters, pinch off tool flaring
tool, charging line, hand shut off valves,
10
combination gauge, air flow meter, Contact less
thermometer, LP gauge, HP gauge, tube bender,
lapping machine)
26. Electrical testing tools for tool room (Digital multi
meters, industrial grade AC & DC ammeter, digital
tongue tester, insulation megger tester, contact less 15
thermometer, digital thermometer, Anemometer,
hygrometer, lux meter)
27. Testing benches comprising following equipment 2
variable voltage supply AC & DC, transistor tester,
meter testing kit,
28. V-belt pre stretching machine (grading machine). 4
29. Portable electric motor driven blower 6
30. 46.7 Ltrs spare Nitrogen (7 m3 ) gas cylinders 4
31. Spare R-134a refrigerant cylinders 6
32. Digital dB. Meter (noise level indicator) 1
33. Oven for drying electrical machines etc. of suitable 1
size.
34. DG set, with canopy 415V of adequate capacity as 1
standby power supply
35. Shock pulse meter 3
36. Tachometer 1
37. Platform jack for handling alternators on the 2
coaches
38. Grease gun for lubricating equipments 1

16.5 TESTING FACILITIES (Electrical)
S.N. ITEM COACH

HOLDING
500(100 AC +
400 NON AC)
1. Pit mounted 25 kW AC test drive complete set (2 1
unit per set) for alternator and regulator testing.
2. Floor mounted 25 kW AC test drive complete set 2
with regenerative load testing for alternator and
regulator testing.
3. Test benches for testing relays & contactors with 1
contacts testing.
4. 1kW Portable motor drive set for testing alternator 3
and regulator.
5. Power supply analyzer, oscilloscope dual channel, 1
storage type
6. Surge comparison tester for testing windings of 1
motor
7. Inverter testing facility 1
8. Inverter card reading & repairing facilities 1
9. WRA/ Mono-block pump testing facility 1
10. Spring testing facility for testing of alternator spring 1
11. Test bench for repairing RRU, ERRU and 2
alternators
12. ERRU testing facility all make 1
16.6 TESTING FACILITIES (Mechanical)
S.N. ITEM COACH

HOLDING
500(100 AC +
400 NON AC)
1. Air brake rake test rig 2
2. Single car test rig (SCTR) 2
3. Water tank test rig 1
4. Ultrasonic testing apparatus 1
5. DV test bench 1
6. SAB test bench 1
7. Test bench for CDTS/Bio-Toilet 1
16.7 MATERIAL HANDLING EQUIPMENTS
S.N. ITEM COACH

HOLDING
500(100 AC + 400
NON AC)
1. Fork lifter 3T 2
2. Fork lifter 1.5T 2
3. Lister 1.5T 6
4. Mobile lifting platform 10
5. Hydraulic pallet truck 01T capacity 4
6. Lorry truck 1
7. Pick up Van 2
8. Push type/ Hand trolley 500 kg 6
9. Material van 2
10. Garbage picking tongs for Bio-Toilets 1Set
11. Tool Bag for maintenance of Evacuation
1 Set
machine

16.8 SAFETY EQUIPMENTS
S.N. ITEM COACH

HOLDING
500(100 SG AC +
400 NON AC)
1. All workmen safety equipments such as industrial As per
helmets, hand gloves, industrial shoes, masks, requirement
minor lamp etc.
2. Fire extinguishers, water hydrants, sand buckets As per
with stand requirement
3. Safety belts As per
requirement
4. First aid boxes As per
requirement
16.9 ADDITIONAL
S.N. ITEM COACH

HOLDING
500(100 AC +
400 NON AC)
1. Computer (PC) with printers with LAN facility. As per
requirement
2. Fax Machine 1
3. Zerox Machine 2
4. Walkie talkie sets/ Mobile sets/P &T phones/ As per
intercom and other communication facilities requirement
5. Water Cooler As per
requirement
6. As per
Storage racks, almirah, locker, furniture etc requirement
7. As per
Bins, container etc requirement
NOTE: Facilities for the items which are likely to be offloaded to trade
should be provided judiciously to avoid wastage of resources.

17.0 SOME MODERN EQUIPMENTS
a. Automated Wheel Diagnostic System (WDS)

b. Automatic in motion Train Washing System
c. Mobile Lifting Platform
d. Bogie/Car body lifting system
e. Under floor bogie repair hoist
f. Turn table
g. Waste removal system for Bio-Toilet
h. Evacuation machine for Bio-Toilet Tanks
18.0 Automated Wheel Diagnostic System
A- Description: Wheel Diagnostic System is a fully automatic and in

motion inspection and testing unit for the diagnosis of wheels of
vehicles in operation.
B- Wheel diagnostic system aims at the following types of diagnostic

work :-
a. Vehicle/wheel set identification
b. Measurement of roundness of wheel and detection of value of
out of roundness
c. Detection and measurement of flat spots
d. Measurement of tread diameter and detection of overshooting
of operational tolerances
e. Measurement of wheel profile and detection of overshooting of
operational tolerances
f. Detection of cracks
Probable source: 1. Hegenscheidt –MFD GmbH & Co Kg
P.O. Box 1652-D-41806 Erkelenz
Website : www.hegenscheidt-mfd.de
Fax- 0049(0) 2431 86 470
Indian agent : M/s VGI Power Systems(P) Ltd.
16-A, Palam Marg, Vasant Vihar
New Delhi-110057
Contact person (India): 1. Mr. Jaspreet Singh
Mobile no. 09810421620
2. SAB Wabco
Cost : Rs.5.0 Crores
18.1 Technology:
A. Wheel diameter/wheel profile measurement (laser based)

The moment wheel passes over the rail, a beam of light is passed on to
the wheel from under it. The emerging rays are received by a receiver
and fed to a computer which evaluates the inputs. By using Opto-
electrical equipments and high resolution digital cameras and
computers which are capable of accurately processing the digital
data, the wheel profile measurement can be performed.
B. Detection of flat areas & out of round

Along a stretch of track equal to the circumference of the wheel, distance
between the track and the wheel crown is continuously measured
electronically and evaluated by a computer. The flat areas are detected by
the variations of height between track and the wheel crown. The difference
between largest and smallest diameter will give the measurement of
out of round.
C. Crack detection
Two ultrasonic scanning heads each are integrated in the left and right rail
of the track, when a wheel passes through the scanning heads, this transmits
ultrasonic impulse for the detection of the cracks on the tread surfaces.
By providing wheel diagnostic system, it will pre-warn the condition of

wheels. This will help in -
 Average planning of wheel profiling and wheel change.
 Improved safety and reliability
 Improved wheel life.
 Reduction in examination time and manpower.
Based on above benefits the provision of wheel diagnostic system is justified.
(Photograph on next page)

18.2 Photograph of Wheel Diagnostic System
18.3 Layout of Wheel Condition Monitoring System
Wheel Condition Monitoring System Remote

• access
Data
exchange
basic
module
database
profile
roundness
Identi- and
and diameter cracks
fication back to
flat spot
back
In Rail Installed Wheel Set Diagnostic System

Inrail Iinstalled
nstalledwheelset diagnostic system

Under Floor Wheel Tyre Turning Machine
under floor wheel lathe machine should be provided in medium & major capacity
coaching depots (coach holding up to ……) the specification and accessories may
be provided in line with DMRC/Depot. The photo of machine with make is as
under-
Photo of Atlas Rail wheel lathe machine

19.0 Mobile Lifting Platform

(Aerial work lift platform)
Description : Battery powered aerial work lift platform with hydraulically
operated scissor lifts.
Source of supply : 1. JLG Industries Inc

1- JLG Drive,McConnellsburg,PA, USA
Contact person (India): Mr.Sunil Jain Reg.Mgr
Mobile no. 09810119569.
2. NeueroTechnologies GmbH, Germany
Cost : Rs.15 Lakhs

20.0 Coach lifting system
Description : Coach lifting system with under floor lifting plant and car
body stand.
Source of supply : 1. Neuero Technologies GmbH

Germany
Indian agent : M/s LAN Railtech. Pvt. Ltd.
K-1/81, C.R. Park, Ist floor
New Delhi-110019 Tel. 011-26271369, 26276449
Contact person : Mr.O.N.Jalota Jt.Managing Director
Mobile no. 09810158226
2. M/s Pfaff
D-86316, Friedberg/Derching,Germany
Lifting Jacks: 1. Jamalpur Workshop, Jamalpur
20.1 Photograph of Coach Lifting System

21.0 Wheel changing system
Description: Elevated track with split rail bridges and wheel set changer
Source of supply : 1. Neuero Technology
Germany
Indian agent : M/s LAN Railtech.Pvt.Ltd.
K-1/81, C.R.Park, Ist floor
New Delhi-110019 Tel. 011-26271369,26276449
Contact person : Mr. O. N. Jalota, Jt. Managing Director
Mobile no. 09810158226
2. Windhoff, Germany
21.1 Photograph of Wheel changing system

22.0 Mechanised Laundry for Linen washing:-

Description: As per Railway Board‟s letter No. 2009/M(C)/165/6 dated
04.07.2012, setting up of Mechanised laundry has now been permitted through
licensing of Railway land. Revised model guidelines for setting up of mechanised
laundry for washing of linen on BOOT model alongwith railway land license
agreement are also attached with the details for implementation.
Where the daily requirement of washed linen is high say 07 tones or above,
the batch washer system (Tunnel washer system) may be considered by the
Railways.
Source of supply:
1. M/s GIABAU Germany.
2. M/s STEFAB India Ltd., West Punjabi bagh, New delhi, Pin-110026
Phone No. 011-41018201, Fax 011-41018207/08.
Batch Pass-Through Dryers Batch Washer
Flat Work IRONER –PSN-80

Details of Basic components of Automated laundry Machines/equipments to

be supplied, installed and operated by Tenderer –
A. Smaller Capacity Laundries:

a. Washer cum extractor
b. Tumbler drier
c. Flat bed ironer/Calendaring machine
B. Batch Washer Systems [Tunnel type]

Washing System: Capable to handle large volume of linen optimizing, water,
electric power, steam and chemicals
- All parts should be of SS 304 or superior.
- Computer controlled system.
- Automatic dosing of chemicals
Pressing System:-
- System should be equipped with a hydraulic press for water extraction.
- Extracted water should be re-used in the batch washer.
- All components should be of SS- 304.
Drying System:-
- System should be fitted with large capacity of pass-through dryers.
- System should avoid bunching of the linen at one end of the drier drums.
- The drier drums should have Teflon coating of the interior.
- Sprinkler should be provided when temperature exceeds set limit.
- The dryers should have an automatic lint cleaning system.
Ironing System:-
- Sufficient Flat-work Ironers to be fitted.
- Ironers (Calendering machines) should have micro-processor-based variable
speed.
Term of concession agreement:-

- Commissioning of the laundry must be ensured within 2/5 months from the
issue of LOA.
- Contract for setting up of an automated laundry on a BOOT scheme shall be
for a period of 10 years (for smaller capacity laundries)
- Contract for batch or Tunnel type washer system for a period of 15 years.
- After commissioning, the ownership of all machines and plants shall be
transferred to Railways in good working conditions without any extra
cost/charge.
- the laundry shall be used by contractor for Railways work only.

Electricity:-
Railways may supply electricity for operation of the mechanized laundry, up to
the limit quoted by the tenderer.
Contractors Responsibility:-
1. Will be responsible for new procurement and commissioning of laundry

equipments.
2. Shall ensure that all effluents from the mechanized laundry conform to
pollution control and other limits.
3. Shall furnish a certificate, valid upto the period of completion of contract for
proposed machines and warranty, AMC etc.
4. Operation of Laundry by skilled technical staff, trained by the OEM.
5. Must follow all labour laws.
6. Shall also provided adequate facility for storage of washed and packed linen
sets in racks made by SS.
7. Use of water proof bags.
Contractors scope of work for linen management.
- Collection of used/soiled linen from AC coach attendants.

- Transportation to the laundry stores.
- Removal of tough stains caused by spillage of food & misuse etc.
- Washing, drying, calendaring, ironing in the automated laundry.
- Packing of linen sets in bags and storage.
- Supply and loading of washed linen sets to attendants in the AC coaches at
platforms washing lines.
- Maintaining proper accountal of linen items.
Quality of cleaning of linen:
- The average whiteness of new linen items after 5 washes shall be taken as
the base reference i.e an index of 100% .
- The contractor must ensure at all the times a minimum whiteness index of
75%.
- The tenderer should also provided instrument for checking whiteness.
- There should be no wrinkles or wetness after calendering.
- The washed linen should be hygienic bacteria free, stain free and odour less.
- To be ensured that the washing procedures and cleaning agents used render
a minimum prescribed service life for new linen items.
01 year for Khadi bed sheets of ACASH
02 years for Poly-vastra bed sheets of KVIC.

Inventory of washed bed rolls:-

- Contractor must make sure that used linen as unloaded from the trains, must be
washed and made available for train services within 48 hours.
- Contractor shall ensure enough “buffer stock” to cater the requirements of at
least 2 to 3 days.
Inspection/Audit check of washed linen:
- Test checks may be ensured on the washed linen kits in conformity with the
guidelines issues in terms of SN- 2 of para 2.1 of Board's letter dated 04
.01.2010.
- During sampling checks if poor quality detected, a penalty of Rs. 3/- per items
may be imposed apart from non- payment.
- In the event of rejection of more than 2% on account of poor washing, the
quantity of that particular lot of linen shall have to be washed again.
- Monthly report of summary of· all inspections/ test checks carried by Officers.
Penalties for unsatisfactory performance:-
1- For non commissioning of Mechanized laundry within 2/5 months from

LOA, LD as per GEC.
2- Rs. 0.50 per item of linen held in excess with contractor.
3- Cost of linen items lost /damaged by contractor to be recovered as per rates
circulated by Railway authorities.
4- In the event of Passenger complaints a penalty of Rs.2,000/- per occasion.
5- In the event of Non- packaging of linen, a penalty of Rs. 1.0/- per packet.
6- n the event of the soiled/used linen not unloaded from the incoming trains,
and fresh linen not loaded a penalty of Rs. 5,000/- per occasion may be
imposed.
7- Penalty up to Rs. 1,000/- per occasion may be imposed for non-Adherence
Contractual conditions.
Passenger Feed Back
1. Passenger satisfaction and feedback is the essence of the linen services.

2. Contractor shall make arrangements for making feedback forms available to
the passengers through AC attendants/ACCI.
3. AC attendants/ACCI shall obtain passenger feedback from atleast 5
passengers per AC coach in each direction.
4. One feed back shall also be taken from Ts/TTE for each direction.
5. Penalty for unsatisfactory work may also be based on the passenger feed
back.

Format for Passenger feed back
WASHED LINEN IN THIS TRAIN IS PROVIDED BY THE AUTOMATED

LAUNDRY SET UP BY M/S_____(NAME OF CONTRACTOR/FIRM AND
TELEPHONE NO.)
Dear Passenger,
Our endeavor is to provide you hygienic linen services. Your valuable feedback
would help us improve further.
Kindly spare few minutes in rating the areas as given in table below:-
Ratings:
5=Excellent, 4=Very Good, 3=Good, 2= Average, 1= Poor
Passenger Feedback- AC Coaches
SN Areas of Service 5 4 3 2 1
Please mark( ) in space
1 Cleaning/Whiteness of Linen
2 Dryness of Linen
3 Ironing & Packing
Passenger Name:
Train No:
Coach No.:
PNR No:
Date of Journy:
Telephone No: Signature of Passenger

Laundry shall be built and operated on BOOT (Build –Own-Operate-Transfer)

Specifications of the Linen:-
S.N Item Specification Existing Suggested

Codal Life Codal life
(Months) (months)
1 Bed sheet Handloom cotton Bed 12
sheet bleached, size
140X229 cms,
2 Bed Sheet Poly vastra size 24
140X229 cms
3 Bath Towels Turkish size 81.3X152 9
cms
4 Hand Towel Hand Towel Turkish, 9
cotton, superior
quality, Size 40X60
cms,
5 Pillow Cover White Pillow cover 9
handloom, size 32X62
cms with 3 cms wide
boarder or all sides
6 Pillow cover Poly vastra 69X46 12
cms.
7 Pillow Size 50X36X10 cms. 24
8 Pillow big size Size 60X36X12 cms. 24
9 Blanket Size 229X140 cms. 48
10 Blanket for AC-I Size 230X152 cms. 48
B-Proposed outlines for linen management:-

1. Complement of linen to be provided in coaches.
2. Specifications of linen items.
3. Managerial control over linen.
4. Infrastructure required for linen management.
5. Infrastructure of mechanized laundry.
6. Machine/Plants required at laundry..
7. Transportation of linen.
8. Stock and Storage of linen.
9. Tendering system for out-sourcing & Tender schedule.
10. Sample test check of linen items.
11. Condemnation of linen.
12. Packing of linen.
13. Permitted quantity of linen with contractor.

14. Various penalties on contractor for linen.
15. Whiteness checking equipment for bed sheets.
16. Daily Position Performa.
17. Monthly Position Performa.
18. Computer programming for stock.
19. Transportation bags for linen items.
20. Likely Sources for linen procurement.
21. Instructions for linen distribution agency i.e. AC/attendants.
22. Existing guidelines/letters circulated by Railway Board.
23. Work distribution among linen cell staff i.e. SSE, JE, Tech. & Clerks.
24. Nomination of officers for control over linen management.

23.0 Automatic Coach washing Plant (ACWP)

Description : Automatic in-motion coach/train washing plant for exterior,
roof and under carriage cleaning with high pressure cleaning jet and with
vertical and horizontal rotating brushing unit .
Source of supply : 1. M/s Wesurail - US
2. M/s Bingham - UK
Cost : Rs.400/- lakhs
23.1 Photograph of Automatic in motion train washing system
Cleaning of coaches is the problem of the entire Indian Railways. Washing

and cleaning of coaches is one of the though and critical jobs to be carried
during train examination. The train movement on the such dusty/sultry
climate of the region, to ensure desired level of cleanliness of coaches of
Railways passenger trains is a real challenge. The rakes of these trains are
examined and maintained at C&W Depot During examination of these
rakes, internal and external cleaning and washing of coaches is being
carried out. It is observed and studied that oily & sticky smoke emitted by
Diesel Locos especially in tunnels result in sticky soot and stains being
formed on the coaches thus resulting in a real problem of cleanliness of the
coaches and this has attracted public criticism also. As the staff is limited,
the desired level of cleanliness cannot be done satisfactorily by

conventional method within limited time period.
23.2 AUTOMATIC COACH WASHING PLANT
To overcome the above problem of coach cleanliness, a method of external
cleaning of coaches by high-pressure water jet pump was adopted earlier.
Seeing at number of staff involvement in carrying out coach cleaning, coach
washing plant is developed by CAMTECH. In this plant, external cleaning
of coaches of a rake was done at NGP, Madgaon & Kurla by horizontal
rotating nylon brushes while passing through.
Eight powered nylon brushes were provided in this plant for the purpose of
rubbing of soap solution and cleaning of dirt on external surface of coach .
1.Stages of
a) Pre-wash,
b) Spraying of pressurized soap solution mixed with compressed air.
c) After wash with high-pressure water jet were developed and
incorporated in this washing plant.
In addition to horizontal nylon brushes, two Coir brush fixtures were
developed and fitted in this plant. These coir brushes were static (non-
rotating type) and fixed in one position for the purpose of even application
and rubbing of soap solution on surface of coach, thereby sticky particles of
soot and dirt get loosened and removed. But this coir brush could not touch
and clean the area near window-sills, upper and lower portions of coach
since upper portion of coir brush was obstructed by coach indication lamp,
indication board, destination board and lower curved portion (turn under) of
coach due to less stiffness of coir brush. Hence these portions were used
to be cleaned manually by available staff.
This plant is developed with keeping in view the following points in mind.
a) Less and economical maintenance of the modified washing plant.
b) Less manpower requirement for operation and maintenance this plant.
c) 95% exterior cleaning of a entire rake of 24 coaches is to be achieved
within 35-40 minutes.
d) Reduction in water and soap solution consumption compared to the
conventional Manual coach cleaning.
e) Reduction in power consumption by using automation.
f) Cleaning and disinfection of underneath portion of toilet by High
pressure jets.
g) Bogie side cleaning by high pressure jets.
h) Roof cleaning of Coach by horizontal nylon brush.
24.0 LAYOUT AND CONSTRUCTION OF AUTOMATIC COACH

WASHING PLANT
The modified coach washing plant is situated at the entry point of rake
examination pit at coaching depot. There are four fabricated structures in
this washing plant.
1) First structure is having plan

area of 17sq.mtr. (5mX 3.4m)
and provided for PREWASH
stage. This structure is erected
at a distance of 30 meter from
second structure, to get
complete soaking of coach
with water.
2) Second structure is having

plan area of 8.16 sq.mtr.(2.4m
X 3.4m), is made from 300 x
150 mm ISBM & 300 x 90
mm „C‟ channel This
structure is provided for the
stages of SPRAYING OF
SOAP SOLUTION and
Rubbing Of Soap Solution by
vertical nylon brushes.
3) Third structure of underneath

pipelines along with air and
water reservoirs having plan
area of (4.5mX3.4m)
15.3sq.mtr. and it is provided
at distance of 16mtr. from
second structure. This
structure is provided for stages
of UNDERNEATH TOILET
PORTION and BOGIE
CLEANING.

4) Fourth structure is having plan area of

48 sq.m.(14m X 3.4m) and provided
for the stages of a) Moistening of soap
solution b) Roof cleaning by a
horizontal nylon brush c)Side cleaning
by four vertical cotton brushes. d)
After wash with high pressure jets.
e)Mopping by two vertical cotton
brushes. and Fourth structure is
erected at distance of 23 mtr. from
second structure, to get sufficient time
for reaction and complete soaking
with soap solution. near washing
OLD STRUCTURE OF PLANT plant.
This structure is located at start of pit line

is aligned and extended to old existing
structure of coach washing plant. It is
also made from same material used for
second structure. Central apron already
exists between the structure & track. It is
provided with proper drainage and
concrete apron in between structure and
track and nearby area at all above
RENOVATED STRUCTURE locations so that waste water and soap
OF COACH WASHING solution will drain out immediately to
PLANT adjacent main drainage and avoid
adverse effect on sleepers and track. Due
to proper apron and drainage,
accumulated dirt and waste are easily
cleaned and maintained with hygienic
condition.

Water is supplied from overhead tank of 40000 ltrs. capacity to underground tank
of 10000 liters capacity (shown in figure). Water from under ground tank is
supplied to coach washing plant for Pre wash and After wash stages, by 3 HP
pump along with stand by, are located inside pump house. Soap solution is made
in overhead plastic tank of 1000 ltrs. and this soap solution is supplied to coach
washing plant for Spraying of solution stage, by one HP pump. Water pipe
connections for Pre wash , After wash , Toilet and Bogie cleaning stages are made
from 1" and 2" pipes and soap solution pipe connection is from 1" pipe. Electrical
switchgears and control panel are provided for 3 Pumps (1 for soap solution and 2
for water),motors (each 3 hp)of 1 horizontal nylon roof cleaning brush and 6
vertical cotton brushes and 2 vertical nylon brushes for soap solution rubbing, in
the pump house which is located near to washing plant. Compressed air supply,
which is already available at pit line, is tapped for soap solution spray.
Both structures and vertical brush unit have been painted with two coats of epoxy
primer and paint. Since this Iron structure and sub assemblies are more prone to
corrosion due to existing salty weather and acidic/alkaline soap solution used in
washing plant, epoxy painting is one of the better options to reduce corrosion and
the cost.

25.0 PROCESS OF COACH CLEANING AND WASHING IN DIFFERENT

STAGES
25.1. PRE-WASH: A rake is moving at speed of 5 KMPH during cleaning
and washing of coaches through this plant. In this stage a diffuser type
sensor is provided for sensing coaches of a rake. As soon as this sensor
senses first coach of a rake, water starts spraying on external surface of
coach through number of holes provided on water pipelines erected around
in a row.
Two sides and roof of
coaches are completely
wetted by low velocity
sprinklers at this stage,
some loose dust & dirt is
washed away from coach
surface and
simultaneously, coach
surface is made uniformly
wet, which help in even
application of soap
solution on coach body.
25.2. SPRAYING OF SOAP SOLUTION: In this stage, diluted soap
solution is sprayed on coach surfaces including two sides and roof through
seven sprinklers. Provision is made for mixing of compressed air with
pressurized soap solution inside the sprinklers to get more bubbles formed
when it strikes with coach surface.
Due to release of surface tension in
bubbles, dirt particles are loosened
and washed away easily. Flow and
quantity of soap solution can be
controlled and adjusted by operating
spindle nut on sprinkler and both
valves provided on soap solution
line and pneumatic line.

25.3. RUBBING OF SOAP

SOLUTION:
This stage is especially incorporated to
get more effective cleaning. In this
stage, soap solution is rubbed and
made even application on both sides of
coach by two vertical nylon brushes
one at each side of coach .This stage
comes into action as soon as sensor at
second stage is activated.
25.4. SOAKING OF SOAP SOLUTION:
In this stage, soap solution is allowed to soak completely for approx.1

minute in normal washing process. This stage is automatically achieved
while rake is moving at 5 Km/h. through coach washing plant, since stage 3
and stage 5 is kept apart at 30 meter distance. During this stage, soap
solution, is chemically reacted with dirt.
25.5. MOISTENING OF SOAP SOLUTION:
In this stage, moistening of partially dried soap solution is carried out by

sprinkling of very low-pressure water through number of nozzles provided
on a water pipe line. Hence soap solution applied on roof and sides of
coach become wet before rubbing by horizontal and vertical brushes.

25.6.COACH CLEANING BY HORIZONTAL AND VERTICAL BRUSHES:

When coach is moving through this stage, first rubbing of soap solution takes
place at roof portion by horizontal nylon brush mounted on top of the IVth
structure.
After this stage, Coach is moving
further through 4 sets of vertical
cotton brush units (2 Nos on each
side). These brushes are moving at
the speed of 150 rpm. Due to
centrifugal force, end of each thread of
cotton brushes start rubbing soap
solution on coach surface with smooth
impact effect thereby whatever
remaining soot and dirt available on
surfaces are taken away completely.
Cotton thread has good capillary
property thus it hold soap solution
continuously for longer time. These
cotton treads have good flexibility and
get required length automatically
according to shape of surface of coach
so that only tip of threads get touched
with coach surface. Cleaning by this
method has shown significant effect.
These cotton threads are specially
given stiffness by fastening with nylon
bristles to prevent mingling of cotton
threads.
Therefore, tips of brushes are
reaching ,touching and doing cleaning
at intricate places on coach body like
window, window sill, window shutter,
doors , space near door including door
handle, space near to destination
board, turn under and roof portion.
Earlier, these area could not be
possible to clean by old coach
washing plant. These brushes are also
helping in removing of reservation
chart pasted on a coach.

25.7. AFTER WASH: In this

stage, washing of roof and sides
of coaches are carried out after
rubbing of soap solution by
vertical and horizontal brushes.
High-pressure water is sprayed on
coach surface through eight high-
pressure sprinklers to wash coach
completely. In this stage, washing
of roof takes place just before
washing of sides by spraying of
water through high velocity
sprinklers provided at top of
structure. This arrangement is
made purposely to allow dirty
water after roof washing to flow
down on both sides of coaches
before washing of sides of
coaches.
25.8.MOPPING OF WATER: After wash, coach body become
completely wet hence it require mopping. Two vertical brushes with
soft cotton threads are provided each on either side. These brushes
start mopping of water particles on sides of coaches as soon as coaches
pass through these brushes.
This stage is specially effective for
cleaning of AC glass windows where
small water drops are always sticking
and staining glass giving discomfort to
passengers when they are looking
outside through such windows. These
brushes are also used for buffing of
coaches to get shining by rotating it in
dried condition when rake is moved
from pit-line after examination. Since,
requirement of soap solution is less for
external cleaning of rake by this washing
plant. Cost incurred in normal external
cleaning of a rake of 21 coaches is Rs.
400 approximately. This cost includes
cost of material like soap solution and
cotton ropes (which are normally
replaced once in a month) and cost of
electrical power.
26.0 INTERNAL COACH CLEANING MACHINE
This machine is departmentally designed and developed for cleaning of

coaches internally. It is operated on 220V AC as well as 110VDC supply
thereby any coach lying any where in the yard can be cleaned by this
machine as 110V DC supply available in a coach. Construction of this
machine is sturdy and light in weight about 6 Kg hence it is easy to handle.
Due to light weight and 1.2 meter length of machine, staff can do effective
cleaning work in standing position without fatigue. At present, this machine
is specially used for toilet cleaning and intensive cleaning of floor, berth,
side wall by using various type of brushes.
FLOOR CLEANING BERTH CLEANING
WINDOW GLASS CLEANING TOILET CLEANING

27. 0 Justification of ACWP proposed for Coaching Depot
Automatic Coach Wash Plant : Cost Rs. 4.0 Crores
Assuming no. of rakes examined per day in a depot = 6 rakes
Average no. of coaches per rake = 21
Total no. of coaches examined per day = 126
Man power required for outside cleaning = 0.6 man/coach
Saving in manpower for 108 coaches ( per day) = 126*0.6
= 76 men days
Considering average wages of Rs.12000/- month or Rs.400/- day
Monetary savings per year = 76x365x400
= 1.11 Crore
The ROR is expected to be about 15 %
Intangible benefits
1. Saving of water with ACWP (with 60% recycling) =6000 litres/rake
Saving of water per day for 6 rakes = 6000x6 = 36000 litres
= 36 kl
Water is a scarce commodity in several areas and conservation of water is imperative

to save this invaluable natural resource.
2. Since the work of external train washing will no longer be carried out at pit line,
drainage problems will be less and the working conditions will improve, leading to better
productivity.

28. Justification of Coach Lifting Plant proposed for Coaching Depot
Cost : Rs.3.0/- Crores
Justification: At present ineffective % of coaching stock in sickline is 2.5 to 3 %. Underfloor

carbody lifting plant is proposed for lifting of coach body for maintenance in the sick line for
reduction in lifting time and safety in operation. By providing UCLP the lifting time of coaches
will be reduced considerably. On an average 4 – 6 coaches are lifted in a major coach depot.
Assuming 2 hrs. saving in lifting and lowering of coach the average saving is about 2 x 5 coach
hrs.
Annual Saving = 2 x 5 x 360 = 150 coaches in a year
----------------
24
Annual saving in Rs. =150 x 30000 = 45 lacs per annum
Further there will be saving of manpower and also ensure safety at work.
29.0 Covered shed

Well lighted all weather covered shed for examination and maintenance of subassemblies as per
Railway Board‟s letter no.97/M(C)/137/1 Vol.VI dt.09.06.04. The proposed pre engineered
building covered shed is cheaper than conventional one (Conventional shed Rs.25 Cr. v/s PEB
shed Rs.20 Cr.) The pre-engineered buildings covered sheds have following features:-
 Simple design and light foundations
 Standard component connections
 Fast and standardized erection process
 Low weight flexible frames offer higher resistance to seismic forces
 Future expansion is simple and cost effective
 Lighter structure weight
 Aluminum sheet offers high corrosion resistance

30.0 Justification for all weather shed for Coaching Depots
Covered all weather shed has been proposed for coaching depots. Detailed justification is as
follows –
1. Earlier the examination was carried out every 1500 Kms. Now with the latest
instructions for coaching train examination, round trip examination is carried out every
3500 Kms. Any laxity in examination is detrimental to the quality, reliability & safety in
operation.
2. Examination has to be carried out in limited time schedule of 6 hours, which involves
external washing, internal cleaning, under gear examination, brake gear checking, wheel
defects examination, change of springs, brake blocks and other defective fittings.
Examination in the open sky is particularly arduous in rainy season and in extreme hot
and cold weather conditions.
3. In case of working in adverse weather like heavy rains, not only the productivity of staff
is affected, it also leads to detaining of rake for longer period of 8 to 10 hours (as
compared to 6 hours scheduled time given for attention).
Financial Justification –
No. of rakes attended per day : 6 nos.

(at 2 pit lines)
No. of coaches attended per day : 126 nos.
(av. 21 coaches per rake)
Loss of time while working in Extreme
weather condition (@ 3 hours per rake) : 126 x 2 = 252 hours per day
No. of days with extreme weather condition : 180 days.
In a year
Total loss of coach hours : 252 x 180 = 45360 hours.
Total loss in coach days :45360/24= 1890 coach days.
Loss in term of earning potential of coaches : 1890 x Rs. 30,000
= Rs.5.67 Crores.
Cost of covered shed : Rs. 20 Crores
Break – even point : Less than 4 years.

Apart from above, there is loss of punctuality due to delayed availability of the rake, which
affects the operation of other trains also. The loss due to poor reliability leading to enroute
breakdowns can be minimized by the use of covered sheds. With the improvement in working
conditions, the quality of safety checks and overall safety shall be improved. Better working
conditions are bound to improve staff morale and are likely to reduce absenteeism due to
sickness resulting from working in adverse weather conditions. Therefore, covered shed is
desirable from techno – commercial considerations.
Better outturn with proposed facilities
With one hour saving in examination time in pitline due to attention of rakes in better working
condition
Savings expected in time required for attention = 1.5 hour
( due to better working condition)
Saving of coach hours (for 108 coaches examined / day) = 178 coach hrs.
As per traffic account figures the earnings per coach per day = Rs.30000/-
Monetary savings (in terms of earning capacity) = 178/24 x 30000 x 365
= 8.1 Crores
This is in addition to manpower savings due to introduction of various M&Ps like Automatic
Train Wash Plant and Wheel Diagnostic System.
Overall Justification:
Cost of project : 60.55 Crores
Savings due to saving in examination time on pit line = 8.1 Crores

Savings due to covered shed = 5.67 Crores
Savings with ACWP = 1.1 Crores
Savings due to Coach lifting system = 0.45 Crores
Total savings = 15.32 Crores per year
Break – even point : Less than 4 years.

31.0 PROPOSED LIGHTING SOLUTION OF COACHING DEPOT
1.0 RECOMMENDATIONS
The illumination level for all working areas i.e. above catwalk, below catwalk
and underpit should be 100-150 lux for smooth and efficient working.
For overhead lighting under covered shed for the purpose of general shed area
and above catwalk lighting, metal halide lamp fittings blended with energy efficient T5
fluorescent lamp fittings with Inverter backup are recommended.
Metal halide lamps are recommended in place of mercury/ sodium vapour lamps
due to its best colour rendering properties. Metal halide excels in meeting the complex
demand of energy efficiency, light quality, light output and lamp life.
The basic problem with metal halide lamp is its high re-striking time (approx. 4
to 6 minutes), to avoid the total blackout during the above re-striking period after
restoring the power supply, the over head lighting is blended with energy efficient T-5
fluorescent lamps at each alternate position.
Multiple T-5 fluorescent lamps with electronic ballast have following beneficial
features:
 Energy efficient (lumens/ watt is 90 to 100)
 Instant start- no flickering & continuous illumination.
 High colour rendering index i.e. true colours
 Uniform distribution of illumination i.e. no shadow area at work place.
 High power factor i.e. more than 0.95.
For illumination below catwalk and under-pit, Power LED based luminaires are
recommended. LED based energy saving lighting have following beneficial features:
 More power to light instead of power to heat.
 Energy efficient (Lumens per watt 90 to 110 lumens).
 Pure white light, high colour rendering index i.e. true colours.
 Long life span, more than 10 years. Eliminates maintenance cost on bulb
or CFL replacements.
For directed maintenance, staff may use helmet based LED lights for precision work.

1.1. OVERHEAD LIGHTING FOR COVERED SHED
Lighting for general shed area.
Illumination required : 100 – 150 lux

Mounting : Overhead fixed on covered shed structure
A-
B- 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 250W METAL HALIDE LIGHT FITTING:
Specification for light fitting luminaire shall be as given below:
Voltage : 230V AC 1, 50Hz
Lamp : 250 watts Metal Halide Lamp

Lamp type : Single ended clear elliptical Metal Halide lamp
Lamp base : E – 40.
Lumen output : 20000 – 22000 lumens
Luminaire : Integral side mounted totally enclosed mid bay luminaire.
Lamp holder base : GES(E40), skirted porcelain.
Reflector : Electrochemically brightened, high purity stainless steel
parabolic reflector with glass assembly.
Glass assembly : Glass and gasket assembly with toggles which shall be swung
open for easy maintenance and shall be secured with chain
arrangement.
Control gear : Heavy duty copper wound ballast, ignitor, and power factor
correction capacitor suitable for 250 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 lamp compartment IP 54.

For control gear compartment IP 43.
IS : Luminaire shall confirm IS: 10322.
Make : Philips, Crompton Greaves, Bajaj, Osram, Wipro, GE, Asian.
SPECIFICATION FOR T-5 FLUORESCENT LIGHT FITTING:
Voltage : 230V AC 1, 50Hz

Lamp : 4 x 24 watt, T-5 energy efficient fluorescent Lamps
Energy efficient high bay fitting made of extruded

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 24W T-5 lamps
system complete with lamps. The fittings shall be provided
with suitable hanging arrangement. Luminaire shall be
provided with acrylic dust cover.
Model : JBFKS 43300 of Asian or similar.
Make : Philips, Crompton Greaves, Bajaj, Osram, GE, Wipro, Asian.
Approx. Dimensions : 600mm x 600mm x 65mm
LIGHT FITTING CONFIGURATION
 Overhead light fittings should be located at the roof structure of the shed just
above the catwalk.
 Distance between the two fittings in a row along the shed length shall be 8.0
metres.
 Light fittings configuration between two rows shall be planned in zigzag manner.
SUPPLY AND CONTROL ARRANGEMENT
Overhead 3-phase, 4-wire system laid with suitable brackets and insulators along
the shed structure under the roof.

1.2 BELOW CATWALK LIGHTING

For lighting below catwalk area.
Required illumination : 100 – 150 lux
SPECIFICATION FOR LED LUMINAIRE
Specification for LED luminaire shall be as given below:
Input voltage : 48 V AC +/- 10%

Input power : 22 Watts
Power factor : > 0.90
LED matrix : 15 LEDs matrix
Approximate light output : 1600 – 1700 lumens.
LED Driver : High brightness driver system
Source : PWM constant current
Reverse polarity protection : Yes
Short circuit protection : Yes
Open circuit protection : Yes
Material and insulation of driver : Fire retardant material (ABS & Polycarbonate)
Diffuser : P12 prismatic polycarbonate & toughened glass
Tj (Junction temperature) : Less than 90° C of each LED after continuous
operation of 12 hrs.
Luminaire type : IR-GOLD-B1 of M/s Goldwyn Limited, 15 & 16, Noida SEZ
Noida – 201305 OR SIMILAR
Dimensions : The approximate dimensions of luminaire shall be as shown below:
150.00
210.00
190.00 ALLEN SCREW 72

ARRANGEMENT
170
270
320
 The whole luminaire fixture shall be provided with high impact resistance i.e. IK10.
 The whole luminaire fixture shall ensure tightness level of IP 67.

 All accessories of luminaire shall be pre-wired upto the terminal block and the connecting
lead wire shall be 3 core (phase, neutral & earth), PVC insulated of suitable size and
minimum 1.0 m long.
Mounting arrangement : Luminaire shall be provided with suitable mounting

arrangement.
Luminaire shall be suitable for semi flush/fully flush/ surface
mounting.
Locking arrangement : The top cover of the luminaire shall be fitted with allen screws to
avoid theft.
Light fitting configuration

 One fitting on each catwalk pillar.
Supply and control arrangement

 48 V AC lines shall be fed from six points by suitable transformers for individual
catwalk.
 Single core copper cable of suitable size PVC insulated 650/1100V confirming to IS :
1554/694 Pt. I-1988 shall run through GI pipe under the catwalk pathway and pillars.
 Cable shall be provided with junction box of suitable size on each pillar for
connection of light fitting. Each row of light fitting shall be provided with suitable
ratings MCCBs.
 Load of light fittings shall be equally distributed on all three phases of supply.
 Metal body of each light fitting should be connected to the earth properly.

1.3 UNDER PIT LIGHTING

For lighting under-pit.
Required illumination : 100 – 150 lux
SPECIFICATION FOR LED LUMINAIRE
Specification for LED luminaire shall be as given below:
Input voltage : 48 V AC +/- 10%

Input power : 16 Watts
Power factor : > 0.90
LED matrix : 12 LEDs matrix
Approximate light output : 1300 – 1400 lumens.
LED Driver : High brightness driver system
Source : PWM constant current
Reverse polarity protection : Yes
Short circuit protection : Yes
Open circuit protection : Yes
Material and insulation of driver : Fire retardant material (ABS & Polycarbonate)
Diffuser : P12 prismatic polycarbonate & toughened glass
Tj (Junction temperature) : Less than 90° C of each LED after continuous
operation of 12 hrs.
Luminaire type : IR-GOLD-C1 of M/s Goldwyn Limited, 15 & 16, Noida SEZ
Noida – 201305 OR SIMILAR
Dimensions :The approximate dimensions of luminaire may be as given below.
ED COATING
PRISMATIC POLYCARBONATE DIFFUSER WITH TOUGHENED GLASS
72
59 65
140 124 WASHER
240 160
290 210

 The whole luminaire fixture shall be provided with high impact resistance i.e. IK10.
 The whole luminaire fixture shall ensure tightness level of IP 67.
 All accessories of luminaire shall be pre-wired upto the terminal block and the connecting
lead wire shall be 3 core(phase, neutral & earth), PVC insulated of suitable size and minimum
1.0 m long.
Mounting arrangement : Same as given in section II.

Locking arrangement : Same as given in section II
Light fitting configuration
 One fitting on each alternate pillar under the rail.
 Opposite pillars under the rail shall have fitting in zig-zag configuration.
Supply and control arrangement
 48 V AC lines shall be fed from six points by suitable transformers for individual
pit.
 Single core copper cable of suitable size PVC insulated 650/1100V confirming to
IS : 1554/ 694 Pt. I-1988 shall run through GI pipe under the pathway and rail
pillar inside the pit.
 Cable shall be provided with junction box of suitable size on alternate pillar under
the rail, fitted with light fitting for connection.
 Each row of light fitting shall be provided with suitable rating of MCCBs.
 Load of light fittings shall be equally distributed on all three phases of supply.
 Metal body of each light fitting should be connected to the earth properly.
2.0 ELECTRICAL LOAD

The approximate electrical load has been calculated considering the design of
coaching complex 620 m long, 14.39 m wide having two tracks as given below.
S.No. Description Qty. Load (in kW)
Overhead lighting
1 250W MH fittings (assuming 300W load with choke) 150nos. 45.0 kW
2. 4 x 24 W T-5 fittings (assuming 110 W load with 150 nos. 16.5 kW
electronic choke)
Below catwalk lighting
1. 22 W LED light fittings (assuming 25 W with driver) 425 nos. 10.5 kW
Under-pit lighting
1. 16 W LED light fittings (assuming 18W with driver) 750 nos. 13.5 kW
Total 85.5 kW
load in kW = 85.5 kW Load in kVA = 107 kVA (Assuming PF 0.8)




COACHING COMPLEX LIGHTING ARRANGEMENT
Exhaust fan
14190
a
a
6000
Ind. fan
3245 3245
5m
4025
250
1800
3m
b b
G.L. 3m Ground Level
d 1300
960 d
1250 785
2000 600
a) Electrical Cables 590
b) Water pipe 3700
250 C
c) Water drainage
250
d) Pit light 850
1. Above design of coaching complex is being prepared by Mechanical Directorate of IRCAMTECH/Gwalior.

2. All dimensions are in mm and not to scale.
3. Circles show the locations of different light fittings.


Additional/Optional
provisions

Waste removal system for Vacuum Toilets (Mobile)

Description : Battery powered waste removal system with rotary displacement pump and
waste tank
Source of supply : Evac , Wedel, Germany
Bio-Toilet evacuation system for Bio-Toilets (Mobile)

Description : Trolley mounted garbage removal system with displacement pump and waste
tank
Source of supply : Vogalsung, Noida, U.P

Waste removal system for Vacuum Toilets (Stationary)

Description : Waste emptying system with rotary displacement pump

Waste removal system for Vacuum Toilets

(Stationary)
Emptying system - Vacuum central










33.0 Suggestions given by Zonal Railways for Pre-Fab pit line &
coaching depot infrastructure during seminar on 21.07.2014
Pit line: Dy CME/NWR, Sr DME/BSP & Dy CME/GKP stated that prefab pit line in line with
DMRC will be suitable but both side catwalks are required alongwith long span supports below
catwalk.
Catwalk: Catwalk is necessary for changing of destination boards, cleaning of exterior,

attention to doors, cleaning of roof and attention to ventilators. But these catwalks make clumsy
situation due to supporting pillars, hence it is suggested that pre-fab longer span catwalks may
be developed for better and safe maintenance.
Pre-Cast tiles: For free movement of staff from one pit line to other pit line at entry point, floor
of pre-cast tiles for atleast half of the coach length should be done for safe travelling.
Lighting arrangement: Light fittings of sufficient lux should be installed on Catwalk pillars for
under gear and trolley inspections. Single phase Welding sockets, and spare plug for hand lamps
should also be provided on this switch board.
Surface wheel lathe machine: Surface wheel lathe machine is required for coaching depots
having holding more than 250 coaches.
Maintenance bay shed: Lay out and estimation for covered shed should be done in line with
ROH depot ADI and TKD. The details may be collected from them.
Hydraulic Jacks: Hydraulics Howrah JET. And Ferro mysore are the sources for lifting
platforms.
Cleaning Machines: Sources for cleaning machines are , Karchar, Roots India, Johnson Divery
etc. Specifications may be collected from them
Revision in codal life of Linen: Some of the Railways have given suggestions that codal life of
bed sheets and blankets to be reviewed for better management of linen items.
******

Draft Guidelines On Maintenance Facilities in Coaching Depots On IR

Uploaded by

Copyright:

Available Formats

You might also like

Draft Guidelines On Maintenance Facilities in Coaching Depots On IR

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Draft Guidelines On Maintenance Facilities in Coaching Depots On IR

Uploaded by

Copyright:

Available Formats

(For official use only)

Draft Guidelines for

We welcome any suggestions from our readers for further improvement.

The correction slips to be issued in future for this handbook will be

CAMTECH/2014/C/FOUNDATION/1.0/CS. # XX date ...………….......

Where “XX” is the serial number of the concerned correction slip

CORRECTION SLIPS ISSUED

Sr. No. of Date of Page no. and Item No. Remarks

2.0 NEW DESIGN OF PRE-FABRICATED PITLINE WITHOUT

As discussed in 12th CMG at Guwahati & CME‟s conference at Mumbai

During the seminar at CAMTECH on 21.07.2014 on the issue, participants

Hand Book on maintenance facilities in coaching depot on IR November - 2014

Automated Coach Washing Plant

Unified Maintenance Pit-line

A unified pitline for internal cleaning of coaches/examination and repair has

2.1 Merits and Demerits of Catwalk

SN Disadvantages of Catwalk Advantages of without Catwalk

Hand Book on maintenance facilities in coaching depot on IR November - 2014

2.2 Covered Shed

 Simple design and light foundations

The cost of pre-engineered buildings is also less in compared to conventional

2.3 Views of Railways have been considered for provision of catwalks.

Railways are sharply divided on view of this facility. While E.Rly,

As discussed in 12th CMG at Guwahati & CME‟s conference at Mumbai and

Hand Book on maintenance facilities in coaching depot on IR November - 2014

3.0 Twin depth pit

4.0 Modern Equipments

To improve reliability, reduce maintenance time and to have state of art,

 Automated Wheel Diagnostic System

5.0 Other Facilities

6.0 Coaching Depot Layout

6.1. The coaching depot is planned for 26 coach length rake.

Hand Book on maintenance facilities in coaching depot on IR November - 2014

a) Automatic in-motion coach washing plant (ACWP)

6.3 Sequence of operation

(a) Train entering into the coaching depot

(b) Outside train washing on automatic in motion coach washing plant

(c) Detection of wheel defect on automated wheel diagnostic system

(e) Placement of rake on maintenance bay for complete maintenance and

(f) Pulling the rake in shunting neck

Hand Book on maintenance facilities in coaching depot on IR November - 2014

7.0 Data/detail of layout of Coaching Complex

7.1 (a) Length of the Coaching Complex = 2104 m

7.2 (a) Thickness of boundary wall = 23 cm

7.3 (a) Width of road = 5 m

7.4 (a) Total track length = 6 km

7.5 (a) Width of the maintenance bay = 14.49 m

7.6 (a) Width of maintenance Sick line = 19.5 m

7.7 (a) Width of Service rooms = 5m

7.8 (a) Width of compressor and exhauster rooms = 5m

7.9 (a) Width of sub-station rooms = 5 m

Hand Book on maintenance facilities in coaching depot on IR November - 2014

Hand Book on maintenance facilities in coaching depot on IR November - 2014

8.0 Features of maintenance bay

8.3. Main features of the maintenance bay are -

8.4 Other salient features:

a. The covered shed is having zig-zag placement of sufficient number of

NB : 1. The sketch of maintenance bay does not have structural and