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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

JUNIOR 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 “Effective Disaster Management�. 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

z

z

Maintenance, Repair and Certification of the entire Rolling Stock Inventory of Indian railways comprising – 2.3lakh Wagons – 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.


ACCOUNTABILITY z

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 –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

Place

Primary Maintenance

Pit Lines in Yard

Secondary Maintenance

Pit Lines in Yard

Platform Turn-around Attention

Platforms

Other End Attention

Platforms

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.


PITLINE MAINTENANCE

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 Cont‌

zThorough

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..

z

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

Running Gear

20

440

Suspension Gear

80

1760

Draw & Buffing Gear

28

616

Brake Gear

65

1430

Under Gear

110

2420

Pipe Lines

46 mts (Aprox)

1012 mts

Total

303

6666


Other Components & Activities Per Coach

Rake of 22 Coaches

72

1584

10

220

14

308

Water to be filled

1600 ltrs

35200 ltrs

Exterior cleaned

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)


PLATFORM MAINTENANCE

Cont..

DESPATCH z

PLATFORM MAINTENANCE

(Examination,cleaning ,watering and certification of platform turnaround trains and pass through trains ensuring safety) z

CONTINUITY CHECK

(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)

z

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

2003

2004

2005

2006

2007

Running Gear

861

1142

653

546

510

Suspension

461

378

445

325

278

Brake Gear

632

634

527

492

464

Draw & Buffing Gear

218

179

129

181

138

Under Gear

473

445

360

245

222


Interior Defects 2003

2004

2005

2006

2007

Plumbing & Water tank repairs

459

425

460

535

449

Main Door, Lav. Door, Passage Door & Vestibules

505

507

332

301

275

Berth & Window Shutters

203

214

228

257

167

Body Panel & Carpentry

188

166

117

87

60

Total

1355

1312

1137

1180

951


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


PITTED WHEEL


SHELLED TREAD


WORK ENVIRONMENT z

Open- to - sky environment facing hot sun , heavy rain, storms, cold weather etc.,

z

Physical handling and working with coach components splashed with human excreta and other animal wastes.

zHaphazardly

and unscientifically constructed Pit lines without sufficient working space and facilities

z

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.)

z Haphazardly

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)

z Absence

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)

z Shortage

of Staff


SPECIAL TRAINS

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

zNo

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

Month

Services

Coaches

Services

Coaches

Services

Coaches

APR

47

818

13

234

21

404

MAY

50

898

32

540

40

880

JUN

27

480

26

454

27

540

JUL

7

108

12

213

12

240

AUG

12

188

16

232

25

152

SEP

14

239

14

252

25

152

OCT

16

260

30

455

43

352

NOV

8

144

45

816

DEC

32

544

50

854

JAN

34

578

54

955

FEB

4

55

15

273

MAR

3

39

0

0

TOTAL

254

4351

306

5278


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. -

z

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

Commercial

Traffic

C&W

Booking clerks

Station masters

Diesel / Electric Loco

TTEs

Yard Staff

Permanent way

Account / Audit

Drivers

Bridges

Guards

Electrical /AC

Controllers

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.

z

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. Driver’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

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.

z No

promotion for SE/SSE with 4600 Grade pay and must retire in same grade.

z Only

about 2% of Technical Supervisors in Indian Railways get promoted as Group – 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


Carriage and Wagon Openline