Steps & precaution to avoid hot axle cases

a. b. Use of chain & wire rope for wheel lifting from CTRB should be avoided and proper wheel lifting tackle recommended by RDSO should be used. Proper Rolling in /Rolling out examination should be done and wagons with flat places should be immediately detached to avoid damage to CTRB. Box feeling or temperature measurement by infra red gun should be done in the yard during examination. During wheel turning following should be checked. Check for loose or missing cap screw. Check for proper bending of locking plate tabs against flats of cap screw Check for damaged end cap due to displaced adaptor Check for loose or damaged seals Excessive accumulation of grease Seal that can be moved laterally by hand or using suitable prove Seal that is cocked out of position in the bearing outer ring Seal that has been damaged from external forces. Seal lips that are damped Old grease accumulation Cracked or broken outer rings Loose backing rings if backing ring can be moved or rotated by hand remove the bearing from service. Proper fitting of adaptor and EM pad as wrongly fitted/canted adaptor, EM pad may damage CTRB. Overload, Uneven loading the wagons may also damage CTRBs P way (gap between rails) also cause impact load which can damage CTRB Awareness of working staff: Working staff should be aware of CTRB working and its different parts. Overdue CTRB should not be allowed. Statistics of maintenance should be maintained properly maintained and analyzed to pin point failure reasons and to take remedial measures.

c. d.

e. f. g. h. i. j.

Precaution to be taken to avoid Train Parting cases CBC Coupler and operating Mechanism:- At the time of coupler inspection, it is important to check and make sure that coupler operating mechanism operated to fully open the knuckle, the handle released and the knuckle slowly closed and lock drop freely and mechanism return to fully locked position. The back position in indicated by the toggle. Only dry lubricant overhaul be use to the coupler head and its fittings. Check correct operation in order to ascertain that full knuckle through lock set, lock to lock (Anti Crop) and locking is obtained of found any defective must be replaced. Check that shank is not bent out of alignment with the head of defective coupler shall be removed. Examine shank wear plate and if worn, fitted new wear plate. Examine wear shank and if wear is approaching 6.5 mm the coupler shall be removed for building up of shank. Examine head for cracks in the side wall if cracked the coupler shall be removed. Check the distance between the nose of knuckle and the guard arm side with Gauge No. 1 if it passes (which is 5.5/16 long) it indicates that the coupler ___ condemning limit. In such a case the knuckle pivot pin, lock etc. should be replaced so that Gauge No. 2 does not pass. If this Gauge passes than the coupler should be removed for ______. Examine the operating mechanism if defective or deficient these components must be changed for free movement. Check knuckle pin, clevis pin to ensure that pin if correct size has been used check _______ arrangements if knuckle pin and clevis pin. Coupler height should checked in accordance with IRCA Part III Rule No. 2.13.7. All defective/deficient components shall be replaced in CBC, clevis and screw coupling. DP test of knuckle should be carried out in schedule overhaul
Operating

a)

b) c) d) e) f) g) h)

i) j) k) l) m)

1.

Failure of inter-vehicle couplers can cause train partings. This can be due to sudden acceleration or braking causing jerky motion of vehicles. Such jerks cause waves of alternate compression and tension in inter-vehicle couplers passing down the train length and the weakest coupler is liable to break. 2. Drivers will observe following precautions to avoid parting of trains: a) When starting a train, attractive effort should be applied gradually to ensure that all the couplings are fully tight. b) Pick up speed notch by notch and start train smoothly. c) Do not release brakes too fast after destroying vacuum by using double exhausters. d) It is not enough to be guided solely by the vacuum gauge. Sufficient time (3 to 5 mt.) should be allowed for full release of vacuum brakes. e) Do not use loco independent air brakes to stop trains. 3. f) Ensure engine coupling is properly tightened / locked before starting a train. When a parting occurs, the driver (in the front portion) should not endeavour to stop the front portion of the train, but should allow the portion to move forward to the extent possible to prevent the possibility of the rear portion colliding with the front portion. The automatic brakes applied on parting may not be effective equally on both the halves of the parted train.

Train Parting When a train in motion is divided in to two or more than two portion, the happening is called as train parting. This may happen which starting, stopping or even during run. Train parting may also take place during shunting operation. The happening may cause an accident and so precautionary measure the driver should keep the front portion in running till such time the rear portion stop. At this time Indian Railway equipped with two type of coupling systems. Coupling System

Screw Coupling

Centre Buffer Coupler

IRS Type

ICF Type

Straight Type

Transition Type

Ordinary

Enhanced

NHT

HT

NHT

HT

In addition to this the EMU stock has been equipped with separate type of coupling arrangement. Reason of coupling failure may be given as under to avoid coupling failure eliminate these reasons. 1. Manufacturing defects a. b. c. d. Material defects Process defects Handling defects Storage defects

Material Defects Material Defects may arise due to the under noted reason and my had to the failure fo the coupling components i) Sub standard material used. ii) Improper Composition of material. Process defects This defects is very important factor with components failure point of view i) Improper method adopted i.e. short cut method. ii) Defective workmen ship. iii) Defective machine and plant. iv) Incorrect turning & _____ provided. v) Improper heat treatment Handling defects After manufacturing of components has not been handled properly if may cause:-

i) Deformation of the components due to throwing, falling on around or other parts etc. ii) Breakage of the components. Storage Defects The material after manufacturing is stored properly if not rightly threw.

It can be corroded due to damp condition. 2. Defective use of coupling: The coupling should always be used with correct proper fitting of the assembly sometimes shunting staff uses coupling just as a loose joining and cause damage to the coupling and assembly. 3. Defective maintenance:- Maintenance is the process to keep the components fit for service to render full capacity use. Thus it is very necessary that correct and timely maintenance should be carried out lapses on part of maintenance can be:a) Overdue maintenance Every components should be attended timely as per schedule but it failed very often due to : i) Non-availability of material required for replacement in shop and open line. ii) Lack of time and facilities. b) Carelessness & ignorance of staff because of i) Operational difficult in repairing and replacement ii) Lack of working experience & knowledge iii) Lack of man power required iv) Lack of tools and plant v) Lack of guidance & insistence to work. Other miscellaneous reasons In addition to the above particulars the coupling also fails due to various other reasons: i) ii) iii) iv) v) vi) Sudden jerk by driver to start Brake binding Excessive train load\ Disturbed coupling by in authorized person Derailments Obstruction on line to cause sudden stop of wheel

CRITICAL ITEMS
S.N. 1. 2. 3. 4. 5. 6. 7. 8. 9. ITEM Rubber kit for load sensing device Spring for side bearer arrangement of BLC wagon Screw 3/213X3/2 and prevailing check nut for ATL Centre Pivot ring for Cast steel bogie Load Sensing Device Spring for ATL ATL DV L Type composite brake block P.L. No. 38972645 38972700 38972724 38972750 38972761 38972773 38972797 38972803 38972815 38972840 38973200 38973303 38973467 38973480 38973741 38973777 38974630 38974812 80014884 Rate/Unit 198.31 725.23 91.21 214 2976.6 2228.10 6446.20 19760 338.21 690.55 73.61 1405.10 1038.20 408.38 349.31 4179.20 2179.30 4668.10 66.71 AAC (2012-13) 5624 5200 1200 500 856 5000 748 244 76000 2620 8580 504 448 408 4036 392 404 162 1180

10. S/Bearer seat 11. Flexible rubber hose 6X50mm 12. Twist head for ATL 13. Bolster spring outer 14. Double check valve 15. Rubber kit for VTA valve (Sabwabco) 16. Rubber kit for DV (Escort) 17. Rubber kit for DV SAB WABCO 18. Center Pivot Top 19. Servo System 68 Oil 20. BLC Wheel 21. E M PAD 22. Wide Jaw Adapter

38981622 38104970

39600 16800

Must change items:

S.N. 1. 2. 3. 4. 5. 6. 7. Item L Type Composite Brake Block EM pad Split Pin 10X100 mm Floating lever centre pin 40X118 mm Floating lever pin 28X100 mm Brake beam wear plate Bush for brake beam

Innovation and Suggestions 1. Interactive training module on kiosk may be introduced to train the staff regarding repair, examination and overhauling of wagons. At present no power back up is available in the depot, hence work suffers . To meet the requirements of the depot, during electricity failure 500KVA DG set is required to run the work smoothly.

2.

3.

4.

The location of depot is in remote area and it is theft prone, however a proposal for boundary wall and fencing is in process but despite of this more RPF persons are required to be deployed or private security may be hired. Recently BLC training school has been started in which trainees from all over Indian Railways are imparted training regarding maintenance of BLC wagons. In this regard an interactive animated module of BLC training is required on kiosk with option of self evaluation.

General 2. Staff Grievance a) Staff grievance cell is functional at WCC/TKD, b) Some private sidings are functional where intensive examination work is carried out, but facilities as per RDSO guidelines are not available. Transportation of examination staff is also an issue 3. Any other issue Constraint a) Scrap from ROH is accumulating at TKD, regular auction/disposal is required and for this covered wagons for loading of scrap should be made available. Amount of scrap is very large and it is overflowing over lines endangering safety of stocks. Pool of spare bogie and wheels should be increased. b) Turning capacity of the wheel lathe is not sufficient for ROH out turn target of 400 wagons/month, hence additional wheel lathe is required if target is to be achieved. c) Against sanctioned strength of 771 staff (including supervisor and ministerial staff) there are only 524 staffs on roll. There is vacancy of 247 staff; this is quite a large gap between sanctioned strength and on roll staff. Acute shortage of staff is adversely affecting day to working of the depot. Work study and number of staff as per enhanced work load has not been assessed since a long time. d) Internet connection is required at depot e) AMC of wheel lathe and computers/printers required. f) Photo copier machine is more than 10 years old and now AMC has also expired it is now required to be condemned and new machine to be procured. g) The case of separate zone for civil engg related work which has been initiated should be pursued and expedited. h) Imprest & dedicated Chief Instructor along with assisting staff for training school i) Imprest for FMM and separate computer trained system administrator/coordinator and trained technician j) Router and other devices installed at Area officer building should be shifted to WCC/TKD along with FOIS terminal; this will ensure safety and proper up-keeping.

For 100% brake power during examination following should be ensured 1. 2. 3. 4. 5. 6. 7. 100% testing of brake power of all intensive examined loads. Ensuring 100% fitment of brake gear components. Ensuring 100% working of critical components like DV, LSD, Brake Cylinder, etc. No skipping of testing of brake power should be allowed SSE concerned must keep the spare of air brake testing / repairing well in advance in the store and keep expediting of store required or pending with AMM. Counseling of staff to enhance their air brake testing knowledge/skill to avoid any mistakes In house training of staff those transferred from coaching depots to freight depots.