Work Profile in C & W Depots of Indian Railways
Presented by M.T.Sujith Kumar SE / C&W / BBQ
ENGINEERS & STAFF OF OPEN LINE SENIOR SECTION ENGINEER
ARTIZANS (THREE GRADES)
Work Areas z As
In-charge of Depot, IOH/ROH Sheds, Sick line, M & P, Stores, Break Down, MIS and Rake Maintenance activities in C & W Depots. z As C&W, M&P and Safety Inspectors in Divisional and Zonal Headquarters. z As Instructors & Lecturers at STCs and BTCs. z As C&W Controllers in Divisional and Zonal control offices.
DUTIES , RESPONSIBILITIES & REQUIREMENTS OF OPEN LINE ENGINEERS
ADMINISTRATIVE DUTIES Depot In-charge z Responsible
for all activities in the Depot. -Technical, Administrative, Ministerial, etc and for Effective execution of administrative policies and plans. z Maintain Out-turn targets and train schedules. z Efficient Stores & Material Management. z Effective Human Resource Management. z Provide on the job training for trainees, apprentices & conducting trade test, suitability test etc.
ADMINISTRATIVE DUTIES Cont.. z Plan
for capacity augmentation in Infrastructure, machinery, plant, material and manpower. z Preparation of Tender & Liaison with out side agencies for Out sourcing, technical suitability, vendor rating, implementation of contractual obligation etc. z Preparation of annual M&P and works programme & maintenance of M&P and related equipments. z Maintenance of Industrial peace, Staff discipline, DAR proceedings etc.
ADMINISTRATIVE DUTIES Cont.. z Ensure
safety of Men, Material and Traveling Public through intensive Supervision and Quality Control. z Maintenance of Accident relief trains including Re-railing equipment, First aid equipment, spares, cranes, etc. z â€œEffective Disaster Managementâ€?. Restoring normalcy during natural calamities and accidents. z Maintain the integrity and punctuality of Train services during natural calamities like flood, storm etc.
TECHNICAL DUTIES z
Maintenance, Repair and Certification of the entire Rolling Stock Inventory of Indian railways comprising â€“ 2.3lakh Wagons â€“ 48500 Coaches for Safe, Reliable and Punctual Train operation. Planning of maintenance activities including placement of rakes in Pit Lines, balancing of rake occupation in Pit Lines. Detachment of Coaches and Wagons for Scheduled maintenance activities like POH and IOH / ROH, etc.
TECHNICAL DUTIES Cont.. z
z z z z
Preventive Maintenance activities of Coaches and Wagons in Pit Lines and Yards. (Examination and rectification of each and every component, for any failures, abnormalities and unsafe condition, which may endanger the safety of the train. Analysis and reporting of component failures. Certification of the entire train for its overall safety till the train returns to the originating station. Maintenance of all registers with respect to train service. Issuance of Brake Power Certificate.
TECHNICAL DUTIES Cont.. z z z z z z
Maintenance and upkeep of Brake Down specials. Planning and execution of re-railment and restoration at accident sites. Maintenance activities in Sick lines and ROH/IOH Sheds. Upkeep of Machineries and plants. Monitoring of trial components. Prevention and analysis of enroute failures like train parting, brake binding, hot axle, etc .
SPECIAL REQUIREMENTS of OPEN LINE ENGINEERS z
Need to posses the complete technical knowledge / working knowledge of the rolling stock as a whole and all its individual components. z Need to posses the technical knowledge of all the Rolling stock manufactured in the past few decades till their complete life span z Whenever new technologies are introduced, adapt to the new technology by self-learning. z Impart training to field staff to update the latest technical developments in rolling stock.
z z z z z z z
Custodian of all assets including Machineries and Plant, Stores and other related equipments worth several crores. Planning and Running of special trains Subject to Audit by the Divisional Audit Personnel. For any failure of the system in train service. For out turn target of wagons/coaches in sick lines and Intermediate / Routine Overhauling. For detention of trains on C&W account For any failure in components of the certified train. For any failure in the brake power.
MULTIFACETED SKILLS & ROLES z z z z z z
Administrative abilities to manage and run Depots. Possess up to date Technical knowledge of various types of Rolling stock and its components. Managerial Skills to manage the work force to meet the quality and safety standards. Assess the knowledge level of work force under him for proper distribution of work. Ministerial skills to ensure proper recording of the data. Technical scrutiny of tender papers for procurement of Rolling Stock components and services.
MULTIFACETED SKILLS ( Cont..) z z z z z z
Tutor and mentor to educate the work force continuously to keep up with modernization. Complete Knowledge of DAR proceedings to tackle erring staff. Planning for improvements. Crisis management for restoration in case of accident or breakdown. Failure analysis and Investigation to find out and rectify the reasons. Maintenance of Accident relief trains including Re-railing equipment, First aid equipment, spares, cranes, etc.
Duties performed by Open Line C&W Engineers during Train maintenance
BASIN BRIDGE COACHING DEPOT Chennai Division / S.Rly is taken for Illustration BBQ â€“The only C&W maintenance depot ISO certified for its entire operations in Indian Railways.
Coach Position of BBQ z z z z z z z
BARE REQUIREMENT INEFFECTIVE (12% FOR AC AND 10 % FOR NON AC) TOTAL (A) TRAFFIC SPARE (B) (12.5%) OF A TOTAL REQUIREMENT (A+B) ACTUAL AVAILABLE SHORTAGE *
755 75.48 ---------830.48 94.38 ---------925 807 - 118
* The shortage results in coaches being cannibalized from other incoming rakes to meet the demand depriving them of the mandatory maintenance time
Coach Maintenance Type
Pit Lines in Yard
Pit Lines in Yard
Platform Turn-around Attention
Other End Attention
Break Down Attention & CSchedule / IOH Attention Maintenance of Accident Relief Trains
Sick Lines / IOH Sheds Yard / Platform
Primary Maintenance -
Need Place Works
Time Day/Night Lighting Validity
Carried out for the Train as a whole Mandatory for every train. Pit Lines in Coaching yards. Safety, Amenity, Electrical, A/C, Internal & External cleaning and Brake power testing with certification. Minimum 6 Hrs in Pit lines. Both Day & Night. Ambient light during day time and primitive minor lamps during night. Up to 3500 Kms Max.
Inspection, testing and attention of all the vital safety components both visually and using inspection tools and gauges to ensure safety of the whole train.
PITLINE MAINTENANCE Contâ€Ś
examination and attention to the brake system to ensure 100 % brake power. zInspection and testing of Passenger emergency alarm system. zEnsuring the availability of correct destination and coach indication boards. zTesting and attention of all Electrical fittings & equipments(, batteries, alternators, lights & fans)
PITLINE MAINTENANCE Cont..
Ensuring availability and working of all passenger amenity and safety fittings. z Exterior and interior Cleaning of coaches using chemicals and detergents. z Watering of all the coaches. z Execution of all Preventive Maintenance schedules.(A & B Schedules as per IRCA part IV)
Vital Safety Components z Running
Gear Components z Suspension Gear Components z Draw & Buffing gear components z Brake gear components z Under frame & Bogie Components z Air-conditioning equipments z Electrical Equipments
Components that must be Examined During Pit Examination Major Components /Coach
Per rake of 22 Coaches
Draw & Buffing Gear
46 mts (Aprox)
Other Components & Activities Per Coach
Rake of 22 Coaches
Water to be filled
120 Sq Mtrs
2640 Sq Mtrs
Window shutters & Fastenings Doors & Fasteners (Main / Toilet) & Vestibules Flush/Push cocks, Taps & Valves
This apart the availability and correctness of more than 145 Cotters & Split pins & 150 Bolts and nuts in every coach need to be physically ensured
PLATFORM MAINTENANCE RECEPTION zROLLING IN EXAMINATION (Visual inspection of dangling parts, hearing for any unusual sound) z
AXLE BOX FEELING
(Sensing the temperature of axle boxes by thermo hunters / hand by kneeling down in the gap between platforms and coach) z
RELEASING OF BRAKES
(Manually pulling of DV release valve by kneeling down in the gap between platforms and coach)
(Examination,cleaning ,watering and certification of platform turnaround trains and pass through trains ensuring safety) z
(Connecting all the air hoses of coaches and ensuring the continuity of air pressure through the formation) z
ROLLING OUT EXAMINATION
(Visual inspection of dangling parts, hearing for any unusual sound)
SICK LINE MAINTENANCE z Execution of preventive Maintenance Schedules
IOH & C- Schedule as per IRCA Part IV. z
Carrying out break-down maintenance. (To maintain the prescribed ineffective percentage of 2.5% of total coach holding)
Any other special works nominated by authorities.
ACCIDENT RELIEF TRAINS z
To be alert on duty round the clock and responding to the accident / derailment with in 20 min. z Arranging protection to passengers and their belongings. z Render first aid and arrange for medical assistance. z Restoration of track and traffic (re - railing) within the shortest possible time. z Investigation of causes and recommendation for preventive action. z Reclamation of assets.
OTHER ACTIVITIES z
Assessment , Procurement and Maintenance of Machinery and Plants & Tools and Plants. z Maintenance of saloons and inspection vehicles. z Planning ,Procurement ,stocking and issue of items required for day to day maintenance activities. z Planning and processing of Outsourcing activities/ services. z Maintenance of Management Information Systems(MIS). z Processing and maintaining ISO certification ,etc.
Defects detected during the last 5 years at BBQ / SR
Defects affecting Train safety Nature of Defects
Draw & Buffing Gear
Interior Defects 2003
Plumbing & Water tank repairs
Main Door, Lav. Door, Passage Door & Vestibules
Berth & Window Shutters
Body Panel & Carpentry
DASH POT SPRING BROKEN
AXLE BOX COVER PUNCTURED
BOGIE FRAME CRACK
BRAKE HANGER PIN MISSING
BSS HANGER MISSING
BUFFER PLUNGER BROKEN
SIDE BEARER PILLAR CRACKED
WORK ENVIRONMENT z
Open- to - sky environment facing hot sun , heavy rain, storms, cold weather etc.,
Physical handling and working with coach components splashed with human excreta and other animal wastes.
and unscientifically constructed Pit lines without sufficient working space and facilities
Exposure / Contact with chemicals and other hazardous compounds used for cleaning due to parallel execution of various maintenance activities (Electrical, Under gear Maintenance, Interior & Exterior cleaning and Airconditioning maintenance)
WORK ENVIRONMENT Cont.. Sewage water stagnation due to improper / defective drainage facilities. z Insufficient lighting with only the primitive Miner Lamps to carry out the maintenance during Night. z Flooded Pit lines during monsoon. z Mosquito , Snake , Rat , Cattle and Stray dog Menace. z Continuous exposure to 110V DC Power system which is detrimental to health. z Exposure to Sulphuric acid in batteries. z
WORK ENVIRONMENT Cont.. z The
staff engaged in inspection of rake/train has to walk a minimum of 1.5 Kms around the rake and has to inspect around 6000 components of safety category with in short span of time by exerting himself by kneeling and standing several times.
Constraints z Insufficient
Pit Maintenance Time
(Due to late running, Interconnection of trains, Bunching of Trains in both Departure and Arrival, Shunting movements, Cross movements,etc.)
and Unscientifically constructed Pit lines without sufficient working space and facilities
(Out of the 19 pit lines at BBQ only 2 conform to CAMTECH norms)
of proper Pit lighting & Yard lighting for Night examination. (Night Examination carried out with only primitive Miner lamps)
Constraints Cont.. z Lack of allocated spare coaches (Resort to cannibalization of coaches from other rakes to replace sick coaches) z Indiscriminate running of Special Trains
without sufficient Coaches. (Resulting in reduced maintenance time for coaches)
These are trains operated throughout the year in addition to the regular trains for various reasons
Special Trains are operated for various reasons. zTo
Clear Wait Listed Passengers z For Summer/ Winter Vacations z During Festival / Pooja Season z During Sabarimala pilgrimage Season z For Organized Tour Package Special Trains / Coaches. z VIP Movements z Inspections z Handing over of Other Division/Zonal Coaches z Trains of Sister Depots for want of Pit lines / Facilities z Dedicated VP Specials ( Parcel Vans)
SPECIAL TRAINS Cont.. z
The coaches for the Special trains are brought from the Traffic spare coaches pooled in Railway Zonal Level which are over and above the holding of the Depot as per the requirement of that Region/Depot.
Demand of Special Trains/Coaches will vary from Region to Region as per the season. z
additional remuneration or Incentive for Running Specials and Extra Coaches is provided to motivate for the extra work load of the special trains which is over and above stipulated work load and norms.
Special Trains Maintained at BBQ 2006 – 2007
2007 – 2008
2008 – 2009
IN SPITE OF ALL THESE PROBLEMS THE TRAINS ARE EXAMINED AND CERTIFIED IN TIME ONLY BECAUSE OF THE COMMITMENT & SINCERITY OF THE TECHNICAL STAFF
Impact of Technical Advancement & Modernization
Impact Cont.. z Unlike
other areas, the benefits of Technical advancements viz- Improved component reliability and modern materials has not reduced the workload of technical staff. -
The number of components to be examined and certified during each maintenance has increased over the years. The responsibility of any failure still rests with the Engineer last certified the train.
Impact Cont.. z
The advent of modern materials and technology resulted in manifestation of new type of defects and problems. -
Introduction of Composite Brake Blocks resulted in 7 new type of wheel failures.
The benefits of technical advancements are offset by increased Kms and Load. -
Validity of certification increased to3500 Kms for Coaching and 7500 Kms for Wagons. Train composition increased to 60 wagons and 25 Coaches. Gross load of wagons increased up to 90 tons
Impact Cont.. z The
modern components with advanced pneumatics and electronic controls demands more discretion and diversified knowledge to maintain and repair. Eg.CD Toilet System Wheel Slide protectors Pneumatic suspension Disc Brakes Coaching CBC , etc
Impact Cont.. z Types
of Wagons and Coaches increased over the years. z No major change in Infrastructure and other facilities. z New technology, materials and system poses newer problems which need to be addressed during maintenance without any prior training or guidance.
Technical v/s Commercial & Traffic Staff directly involved in running of trains Technical
Diesel / Electric Loco
Account / Audit
Signal & Telecommunication
RECRUITMENT, QUALIFICATION AND TRAINING JUNIOR ENGINEER (GP 4200) z
50% - Direct recruitment through RRB 3 Years Diploma in Engineering & 1 ½ Years In- plant training. (Total 4 ½ Years Qualification equal to Engineering degree) z
VI CPC observation that JE and Clerk are equal since both have 3 years Qualification is wrong since JE has total 4 ½ years Qualification.
Hence both pay cannot be equal and needs correction. correction
JUNIOR ENGINEER Cont.. z
z z z
The Duties and Responsibility of a JE is enormous when compared to a clerk with whom he is equated. JEs in open line bears highest responsibility in safe running of trains. Have a direct element in running of trains along with drivers. Driverâ€™s function start only after the issuance of BPC by Open line engineer
SECTION ENGINEER / Sr.SECTION ENGINEER (GP 4600) z z
Both scales merged as SSE Composition of cadre – 20% Direct recruits with 4 / 4 ½ years Degree in Engineering
and One year In-plant training – 80% promoted from Junior Engineers (4 ½ Years total qualification and 20 to 25 years of Experience) z
VI CPC observation that this category is equal to any other Bachelor degree holder in arts, science or commerce is totally wrong. SSE with such huge responsibility and accountability and Office Superintendent cannot be kept in same scale in any angle of observation
AVENUES OF PROMOTION z Only
one promotion for JE-II/JE- I from 4200 Grade Pay to SE/SSE with 4600 Grade Pay.
promotion for SE/SSE with 4600 Grade pay and must retire in same grade.
about 2% of Technical Supervisors in Indian Railways get promoted as Group â€“ B officers.
Even after this analysis submitted in this study, if one decides that JE = Clerk SSE = OS Then GOD only can save railways and only GOD need to be appointed as Pay commission chairman Observation by IRTSA