CONTENT

1. Introduction 2
2. General observation on strength and shortcomings 3-5
3. Quality audit check sheets 5-36

Page 1 of 36 Quality Audit of Wagon Depot

1. INTRODUCTION
As per order of PCME/WR, AME/HQ has conducted Internal Railway Quality Audit of Gandhidham
Wagon Depot for ROH, Yards and Sick Lines during the period 20.11.2024 to 22.11.2024.
Locations visited and covered during the Audit are as under:

Sl. No. Location Date

1. Yard Gandhidham 20.11.24
2. ROH Depot Gandhidham 21.11.2024
3. Sick Line Gandhidham 22.11.24

Scope for Quality Audit of Wagon Depot:

1. Quality audit of wagon depot for ROH attention of freight stock (Air brake stock fitted with CASNUB
bogies and BTPNE wagon).
2. Quality audit of wagon depot for Yard attention (Intensive examination) and sick-line attention.
3. Quality audit of Wagon Depot with regard to maintenance of Stainless Steel Wagon (BOXNHL /
BCNHL/BRN22.9

Page 2 of 36 Quality Audit of Wagon Depot

 GENERAL OBSERVATION ON STRENGTHS AND SHORTCOMINGS

Strength:-
1. Trolley dismantles properly and underhand welding is done during ROH.
2. 100% CBC knuckles are DP tested during ROH.
3. Manipulator/devices worth noting
 Bolster Manipulator in ROH depot
 Bogie Manipulator in ROH depot
 Spring height measuring arrangement in ROH
 BOXN door straightening arrangement in Sick line
 Computerized (Digital) Rake Test Rig in yard
 Use of mobile work stations containing jacks and other tools
4. Total 9 gangs have been deployed in yard examination to mitigate the work load.
5. IT cell in yard for monitoring FMM has been standardized.
6. Turn table provided at cross track in ROH depot.

Shortcomings;
ROH:-
1. Test benches for the Slack Adjuster Barrel (SAB), Distributor Valve (DV), and Brake Cylinder (BC)
are unavailable.
2. The Elastomeric Pad Height Gauge is currently missing. At present, the ROH staff is using a steel rule
to measure the height of the elastomeric pads. The standard height is 46 mm, with a condemning limit of
42 mm.
3. A standard gauge for measuring the free slack of the coupler body is not available. Currently steel rule
is used to measure the free slack.
4. The dye penetration test on critical brake beam points is not being conducted during ROH.
5.Standard gauges for measuring the center pivot bottom clearances of both type Center pivot bottoms
(spherical and flat type) are not being used. Locally made gauges are currently being used.
6. The standard gauge for measuring friction snubber wedge wear is not being used. Locally made
gauges are being used instead.
7. Silico-manganese liners for the pedestal jaw and brake beam are unavailable. Currently, mild steel
liners are being used, which do not meet the standard specifications.
8. Some items in the “Must Change” list, such as the striker casting wear plate and MU washers, are in a
critical stage and need to be recouped on a regular basis.
9. Modification works for MBS wagons are conducted regularly, but kits for Escort make MBS wagons
and KNORR make cylinders for MBS wagons are not available at the depot.
10. Scrap materials are not being segregated properly, although a scrap yard is under development for
Page 3 of 36 Quality Audit of Wagon Depot
different types of scrap.
11. During the ROH of the wagons, contractor staff were observed not wearing proper PPE kits and
uniforms.
12. The standard gauge for measuring the gap between the sensing point of the APMD sensing arm and
the top of the side frame is unavailable. Currently, a locally made iron block piece is being used, which
requires calibration.
13. The three-phase welding socket for welding machine at the depot is outdated, leading to frequent
electricity failures during the welding process.
14. A dust-proof CTRB room is not available at the ROH Depot, GIM.

Sick Line:-
1. The distance between the two tracks in the sick line does not conform to the required standards.
2. Insufficient lighting along the length of all four lines is hampering night-time operations.
3. Test benches for the Distributor Valve (DV), Slack Adjuster (SAB), and Brake Cylinder (BC) are
currently unavailable.
4. The concrete pathways along all lines are in reconstruction phase along the pathways and lines.
5. A step gauge to measure the clearance between the bogie and adapter is not available.
6. A standard gauge for measuring the gap between the sensing point of the APMD sensing arm and the
top of the side frame is unavailable. Currently A locally made gauge is being used as a substitute.
7. Safety instruction boards are not installed at the site.
8. The Elastomeric Pad Height Gauge is missing. At present, the sick line staff is using a steel rule to
measure the elastomeric pad height, which should ideally be 46 mm, with a condemning limit of 42
mm.
9. Separate Earthing feeder pillars for welding machines are installed in 2 machines, and for 3 machines
earthing is done through armored cable.
10. Silico-manganese liners used for pedestal jaws are unavailable. Currently, mild steel liners, are
being used.
11. A standard gauge for measuring the free slack of the coupler body is not available. Currently steel
rule is used to measure the free slack.

Page 4 of 36 Quality Audit of Wagon Depot

 Examination Yard:-
1. While rolling-in examination lights are installed on all lines, rolling huts are not available on any of the
lines.
2. Rolling-in examination lights are not provided on one side of lines 3, 4, and 5.
3. Illumination for bogie and under gear examination is inadequate.
4. A concrete pathway from the yard office to the old examination line is not available, obstructing the
movement of staff and materials.
5. The standard gauge for measuring the A-dimension is unavailable. A locally made is currently used.
Which needs to be calibrated.
6. The standard gauge for measuring the gap between the sensing point of the APMD sensing arm and the
top of the side frame is unavailable. A locally made is currently used. Which needs to be calibrated.
7. Scrap was observed on the examination line, with no proper segregation or designated disposal site.
8. A stopwatch for recording release times during rake air brake testing is unavailable. Staff are currently
relying on mobile phone stopwatches for this purpose.
9. Both buffer height measuring gauges and wheel diameter measuring gauges are unavailable. Currently,
they are being used from the sick line.
10. The step gauge for measuring bogie clearance between the adapter and the side frame is unavailable.
11. The width between the old examination lines 2 and 3 does not meet the standard requirement.
12. Separate Earthing feeder pillars for welding machines are not installed in any of the welding machines.

Page 5 of 36 Quality Audit of Wagon Depot

 Quality Assurance Directorate (Mechanical)RDSO Lucknow

Quality audit check-sheet for ROH attention of

Freight Stock (Air brake stock fitted with CASNUB bogies and BLC wagon)

(Based on CAMTECH Maintenance Manual for Wagon and CAMTECH report on Standardization of
Infrastructure Facilities for Freight stock maintenance)

SN Requirements Clause Observations

1 ROH ATTENTION

1.1 ROH periodicity for various types of common wagon as stipulated is Table 2.3
being followed: of wagon
manual,
SN Type of stock Periodicity of ED
ROH (Months) committee
1 Stainless steel wagon 18 month (for report and ROH of BOXNHL/BCNHL wagon
(BOXNCR/BONLW/BOXNHL) new stock RB’s done
BOXNHL – 1ST guideline
ROH - 24 for ROH of
months) BOXNHL
ROH of BOXN wagon done
2 Other Open Wagon 18 (2007/
3 Covered wagon 24 M(N)/ 951 /
4 Hopper wagon 24 45) ROH of BCN wagon done
5 BOY wagon (22.9) 18 Not done in GIM ROH Not
6 BOBS wagons 18
7 BOBYN 24 done in GIM ROH Not
8 Bogie tank wagon (BTPN) 18
9 BTPGLN 24 done in GIM ROH Not
10 BVZI 12
11 BLC 24 done in GIM ROH Not

done in GIM ROH

IOH Done in 12 Months

Not done in GIM ROH.

1.2 ROH OF AIR BRAKE WAGON WITH CASNUB BOGIE Para 205 (Chapter 2) of CAMTECH Wagon manual.

Page 6 of 36 Quality Audit of Wagon Depot

1.2.1 a) Lift the body, keep it on trestles and run out bogies Followed
b) Strip bogie component for examination and repair as below:
 Strip spring & spring suspension arrangement including Followed
snubbing device.
 Check springs for free height and other defects. Replace
Followed
where required.
 Examine Bogie frame. Check frame alignment as per Examined as per G-64
instructions contained in RDSO Technical Pamphlet No. Followed
G-64.
 Examine pivot for welding defects/cracks/ abnormal Followed
depth due to wear. Replace where necessary and
lubricate with graphite flakes to IS:495 in dry condition.
c) Strip brake gear levers and rods for examination of worn
out/damaged parts.
d) The equipment shall be given attention in accordance with DV overhauling is not done in GIM, DHD
the maintenance manual issued by respective air brake Workshop supplies OH DV’s.
equipment manufacturer:- Followed
 Cleaning of strainer discs (Reference 6 & 218 of the
pamphlet SBA 795/258 of P4aG type Distributor Valve)
Checked for operation
 Lubrication of brake cylinder/cleaning of its strainer
 Check for easy operation of isolating cock & anti-
pilferage device of distributor valve cut-off angle cock ,

Page 7 of 36 Quality Audit of Wagon Depot

SN Requirements Clause Observations
manual quick release valve & isolating cock.
 Draining of Auxiliary Reservoir Done
 Checking of hose coupling for serviceability Done
 Cleaning of strainer Done
 Dirt collector to be cleaned Cleaned
 Leakage in pipes and joints to be checked Checked
 After carrying out above items of work the wagon shall
be tested for proper function of air brake system with
single car test device in accordance with the procedure
indicated below :
 Connect the BP coupling of single car test rig to Followed as per G-97 for air brake system
the corresponding coupling of the wagon to be
tested .The couplings of the other end of the
wagon to be closed with dummy coupling heads
.Fix pressure gauge on the brake cylinder. Followed as per G-97 for air brake system
 The single car test device should now be coupled
to the main line of a compressor through a pipe.
 Carry out the preparation and testing in
accordance with the procedure given in the
manufacturers Maintenance Manual and record Followed as per G-97 for air brake system
the reading in the test proforma. Followed
 For passing the wagon, all the parameters shall be Examined
within specified limits Followed
e) Clean horizontal lever, hand brake & gears and lubricate
f) Examine head stock for damage, bent/cracks
g) Refit brake gear levers and rods, lubricate pins and other Replaced
equipment and apply graphite to horizontal levers of empty
load box
h) Replace worn out brake blocks
i) Check wheel profile, turn the wheels as needed. UST of Axle 100% wheels are being tyre turned at
to be carried out & turning of wheel to worn wheel profile GIM depot along with UST
during ROH
j) All the wheels are to be checked ultrasonically and Axle box 100% wheels are being tyre turned at GI
cap bolts are to be tightened up by torque wrench with proper depot along with UST
torque and in no case old locking plates are to be reused.
k) CBC Knuckles are to be checked by contour gauge, anti- Checked with gauge and anti-creep
creep/ articulated rotary operation of locking arrangement to checked manually
be checked.
l) Manual adjustment of brake gear to be done in accordance Followed
with wheel diameter.
m) Modification works are to be attended as issued by RDSO Followed as per manual
from time to time.
1.2.2 During ROH attention, schedule Items as per table 2.4 of Table 2.4
CAMTECH manual for wagons are attended as under (Chapter 2)
a) BODY REPAIR WORK (Common for all) of
 UNDERFRAME- Sole Bar CAMTECH Done as per requirement
 Scrap the portion of sole bar at doorways, clean and Wagon
apply primer paint followed by Topcoat manual.
 SIDE WALL- Skirting Done as per requirement
 Check and patch if corroded then apply primer and
top coat on the patch Done as per requirement
 Side Doors- Check damage and repair clean &
lubricate hinges
Done as per requirement
 Side Pillars- Check cracks at the base & repair.
 Patching of body, roof, door or floor plates Done as per requirement
straightening buldged ends repairs to angle irons,
stanchions and crib angles etc. Done only in covered wagons
 Making wagons water-tight (Covered wagons)
 Fitting/replacement of door fastening road, door Done as per requirement
cotter pin eye, bolt hook and eye locking pin on
empty wagons and closing of doors.

Page 8 of 36 Quality Audit of Wagon Depot

SN Requirements Clause Observations
 Fitting/replacement of door fastening rod guide, door Done as per requirement
hasp which requires riveting on empty wagons.
Repairs by welding to door fittings.
 Hand rail/foot board deficient/or damaged, Done as per requirement (During IOH of
insecurely fastened at door way of guard’s brake BVZI & ROH of BVCM.
van

b) UNDER GEAR REPAIR WORK ( Common for all )

 Brake Linkage- Check free movement Ensured proper working during repair
 Hand Brake - Check proper working Ensured proper working during repair

c) BOGIE REPAIR WORKS (CASNUB BOGIE)

 BOLSTER
 Pocket slope liner Change liner if thickness less Followed
than 5 mm
 Rotation stop lugs Provide liners (thickness to suit) if Followed
dimensions less than 514 mm
 Inner Column Gib Provide liners (thickness to suit) if Followed
dimension more than 142 mm
 Land surface Provide liners (thickness to suit) if Followed
dimension less than 442 mm
 Outer Column Gib Renew by welding if dimension Followed
more than 241 mm
 SIDE FRAME
 Column Friction Liner - Change liner if dimension Followed
more than 455 mm
 Column sides - Provide liners (thickness to suit) if Followed
dimension less than 209 mm
 Anti rotation lugs - Provide liners (thickness to suit) if Followed
dimension more than 526 mm
 Key seat to pad 22 W - Provide liners (thickness to Currently not in service
suit) if dimension more than 276 mm
 Crown Roof 22WM - Provide liners (thickness to Currently not in service
suit) if dimension more than 321 mm
 Crown Roof 22NL - Provide liners (thickness to suit) Followed
if dimension more than 326 mm
 Pedestal Crown Sides - Renew by welding if Followed
dimension less than 147 mm
 Pedestal Jaw 22 W - Provide liners (thickness to Currently not in service
suit) if dimension more than 275 mm
 Pedestal Jaw 22 WM - Provide liners (thickness to Currently not in service
suit) if dimension more than 283 mm
 Pedestal Jaw 22 NL(Short) - Provide liners Followed
(thickness to suit) if dimension more than 195 mm
 Pedestal Jaw 22 NL(Long) - Provide liners Followed
(thickness to suit) if dimension more than 241 mm
 Pedestal Sides 22 W - Provide liners (thickness to Currently not in service
suit) if dimension less than 102 mm
 Pedestal Sides 22 WM - Provide liners (thickness to Currently not in service
suit) if dimension less than 102 mm
 Pedestal Side 22 NL - Provide liners (thickness to Followed
suit) if dimension less than 78 mm - - X X
 WEDGE
 Slope Surface - Renew by welding if dimension less Standard is 61.5 mm liner should be
than 7 mm applied of 3 mm
 Vertical Surface - If vertical surface from center line
of spigot less than 56 mm provide liner of 6 mm
thickness

Page 9 of 36 Quality Audit of Wagon Depot

SN Requirements Clause Observations
 CENTRE PIVOT (BOTTOM)
 Vertical Side 22 W - Renew by welding if wear more Currently not in service
than 4 mm
 Vertical Side 22 WM - Renew by welding if wear Currently not in service
more than 3 mm
 Vertical Side 22 NL - Renew by welding if wear Followed
more than 3 mm
 Seat Side 22 W Renew by welding if wear more Currently not in service
than 3 mm
 Seat Side 22WM Renew by welding if wear more Currently not in service
than 3 mm
 Seat Side 22 NL Renew by welding if wear more Followed
than 3 mm
 COIL SPRING
 Outer - Group and use in sets. Replace if free height Followed
at or less than 245 mm
 Inner - Group and use in sets. Replace if free height Followed
less than 247 mm
 Snubber - Group and use in sets. Replace if free Followed
height less than 279 mm
 ADAPTER
 Crown Surface Replace if worn 3.5 mm or more Checked and Replaced
Side lug Replace if wear more than 3 mm on either
side
 Thrust shoulder Replace if depth exceeds 0.7 mm Checked and Replaced
 Machined relief Replace if depth less than 0.8 mm Checked and Replaced
 Adapter Bore Diameter Gauge Checking on all Adapter Followed
(New or Serviceable)
 BOGIE BRAKE GEAR
 Pins & Bushes - Change if clearance more than Checked and Replaced
1.5 mm
d) AIR BRAKE SYSTEM
 Distributor Valve Overhauling Overhauling Not done in GIM ROH
 Distributor Valve - Test on SWTR Overhauled DV supplied by DHD
 DV Isolating Cock - Examine operation workshop.
 DV Release valve - Examine operation Examined and checked.
 DV Filter - Clean
 BRAKE CYLINDER Overhauling done at DHD and PRTN
 Filter of Escorts & RPIL make - Clean Brake workshop
Cylinder of Greysham & WSF make Lubricate
 CUT OFF ANGLE COCK Examined and checked
 Angle cock Examine and lubricate
 DIRT COLLECTOR
 Dirt Collector - Clean Examined and checked
 Sealing Ring - Change Examined and checked
 RESERVOIR
 AR & CR - Drain Examined and checked
 Sealing Ring - Change Followed
 METAL PIPES & JOINTS
 Pipe Joints Examine leakage & repair Checked and if found leakage then
 Seals (20 mm & 32 mm) pipe - Change replaced
 Guard’s Emergency Brake Valve - Examine Examined and checked
operation
 Isolating cock of BVZC Brake Van - Examine Examined and checked
operation
 Quick Coupling - Examine operation Examined and checked
 Load Sensing Device - Examine operation Examined and checked
e) SLACK ADJUSTER ( COMMON FOR ALL)
 Slack Adjuster - Test Functioning, repair if required Done
 “A” dimension - Adjust Done
 “e” dimension - Adjust Done
 M20 Anchor Pin nut - Ensure securing by welding to pin Done
 Air Brake System - Test on SWTR as per procedure Done

Page 10 of 36 Quality Audit of Wagon Depot

SN Requirements Clause Observations
 Brake Block - Ensure Std. Key, Spilt pin & all new brake Followed
blocks
f) CENTRE BUFFER COUPLER ( COMMON FOR ALL)
 CBC BODY
 Coupler Body - Examine & replace on condition Examined
basis
 CBC Contour - Examine, replace if required Examined
 Shank Wear Plate - Replace on condition Examined
 KNUCKLE
 Nose - Replace if wear more than 9.5 mm with Followed
HTE knuckle
 Knuckle pin - Replace on condition Followed
 Knuckle Stretch - Examine, Replace if required Followed
 STRIKER CASTING
 Wear Plate - Replace 100% Replaced During ROH
 Striker casting - Replace on condition Changed as per rejection
 COUPLER MECHANISM
 Anti Creep Protection - Examine and repair. Examined
 Lock lift assembly – Examine Examined
 Operation Mechanism - Examine Examined
 Lock - Examine Examined
 DRAFT GEAR
 Slack Measure & take correction Changed as per rejection rule
 GENERAL
 Yoke pin support - Replace on condition Replaced on Condition
 Buffer Height Examine & Correct if required Examined

g) WHEEL AXLE & BEARING ( COMMON FOR ALL)

 AXLE
 Ultrasonic Testing - To be carried in every ROH & 100 % wheels are being tyre turned at
reject if fails GIM ROH depot along with UST
 Deep Notches due to gearing of pull rod - Reject if Checked
depth is more than 5 mm
 Axle end holes - Clean and lubricate in case end Done
cover is opened
 WHEEL
 Tread profile - Check with tyre defect gauge Checked
 Height of flange - Check with tyre defect gauge Checked with Tyre defect Gauge
 Smooth flange - If flange not completely smooth do Checked with Tyre defect Gauge
not use under ROH wagon
 Wheel profile - Turn to WWP if above clause are Followed
not met for use under ROH wagon.
 Cartridge Tapered Roller Bearing
 Cup - Rotate the bearing for unusual sound check Checked and started standard practice
up for Crack/chipping
 Seal - Check seal for external damage/dent Checked
 Backing Ring - Check backing ring for looseness &
vent fitting on backing ring with vent hole ( the vent Checked
fitting should be intact or the vent hole should be
plugged)
 Locking Plate - Use new locking plate when ever 100% changed
and cover is opened
 Axle end Cap screw - Clean and lubricate in case Checked
end cover is opened
 Load Zone Change - Change load zone area of Checked
the cup while lowering bogie side frame

Page 11 of 36 Quality Audit of Wagon Depot

SN Requirements Clause Observations
1.2.3 During ROH attention of bogie Nominal & Maximum Clearances in Table 2.4 Maintained as par Manual
CASNUB Bogie are maintained as per table 2.4(Chapter 2) of (Chapter 2)
CAMTECH wagon manual. of
CAMTECH
Wagon
manual.
12.4 For BVZI wagon, bogies should be given IOH attention at depot. RB letter IOH done at interval of 12 months
POH after 24 month to be done at workshop no.
2003/M(N)
/ 951 / 17
dtd
30.03.11
1.3 ROH attention of BLC wagon RITES BLC ROH schedule not done at GIM
maintenanc
emanual
for BLC
wagon
1.3.1 After placement
a) Visual checking of head stock for bent, crack as well as bogie
maintenance
b) Pre-testing of wagons: Test the wagon individually by SWTR to
ensure the condition of DV, BC, angle cock as well as pipe line for
any leakage
c) Check the DV isolating cock, manual quick release valve
d) Disconnect ‘A’ car from ‘B’ car – remove Yoke pin bolts, nuts with
split pins and yoke pin support. If yoke pin is not dropping itself a
bump through draw bar may enable the yoke pin to drop by its
weight.
1.3.2 Disassembly of Bogies
a) Disconnect the bogie brake rigging arrangement including rubber
hose pipe and raise the wagon body after removing split pin, lock
pin. Shackle lock etc. by using suitable over head cranes or 25 T
whiting jack. Remove side frame key.
b) Run out the bogies. Lower the under frame on the trestles. Remove
the bogie by lifting with 4T capacity crane from the wheel sets.
Place on fixture. Take out the bolster for repair.
1.3.3 After Lifting:
a) Strip Springs & Springs Suspension arrangement. Check Springs
for Free height and other defects. Replace when required. It is
recommended that Springs having not more than 3mm Free Height
variation should be assembled in same group. Mixing of New & Old
Springs should be avoided.
Springs should be marked as per grouping.
Spring Free Height
Nom Cond.
Outer 260 245
Inner 243 228
Snubber 288 274
b) Examine Bogie Frame, Frame Alignment by Dismantling the Bogie.
Side frame to be checked by proper gauges to inspect wear & tear
of friction liners. Worn out portion to be built up by proper welding in
down hand position. Worn out liners to be replaced.

A. BOGIE SIDE FRAME Nominal (Wear

Limit)
i) Friction Wear Plate 10 (2+2)
ii) Column Side 216 (5+5)
iii) Anti Rotation Lug 450 (3+3)

Page 12 of 36 Quality Audit of Wagon Depot

SN Requirements Clause Observations
B PEDESTAL CROWN Nominal (Wear
Limit)
i) Key Seat to Pedestal 318 5
ii) Pedestal Crown Side 152 4+4
iii) Pedestal Side 105 2+2
iv) Distance between Outer & 278 4+4
Inner Pedestal Jaw
v) Crown side 152 4+4

C ADAPTER Nominal (Wear

Limit)
i) Crown Lug 156 4+4
ii) Side Lug 130 3+3
iii) Adapter Side 268 3+3
D. BOGIE BOLSTER. Bolster Nomi- (Wear
pocket has 8 mm thick Si-Mg steel nal Limit)
liner in slope pocket, may be
permitted in service up to 3mm thick.
Replace worn liner. No paint or
grease should be applied on liner.

i) Bolster Land Surface 443 3+3

ii) Thickness of Slope Surface Liner 8 3+3
iii) Rotation Stop Lug 518 3+3
iv) Bolster Column Jib Outer 241 5+5
v) Bolster Column Jib Inner 136 5+5

E. Center Pivot (Wear

Limit)
i). Wear Limit Vertical side 2
ii) Seat. 2

F Elastomeric Pad
i). The top or the bottom plates should not show any
cracks. If any sign of crushing of rubber is noticed
reject the pad.
ii) Permanent set in free height is allowed to 42 mm
instead of 46 mm normal size. Use up-to 44 mm in
ROH

G Side bearer Nom Cond

Side bearer springs are 123 119
condemned on the basis of height.
It is recommended springs having
variation up to 2 mm in free height
are only assembled in the same
bolster. Mixing of new and old
spring should be avoided.

H Wedge Block Wear limit

i). Wear in Vertical 7
Surface from C/L of
Spigot.
ii) Slope Surface by 3
Gauge

Page 13 of 36 Quality Audit of Wagon Depot

SN Requirements Clause Observations
I Bogie Dimension Nominal Tolerance
i) Cross Trammel 3018 ±4.5
ii) Journal Center 2060 ±5
Distance

1.3.4 Brake gear attention is given as under:

Brake Gear Repairs

i) SAB (set ‘A’ dimension to 72 +2, -0 mm)
ii) Control Rod – Replace on condition basis
iii) LSD (maintain gap 8 to 10 cm)
iv) Hand Brake Wheel – operate and attend
v) Hand Brake Connecting Rod – check and
replace on need basis
vi) Ext. Roller Bracket – check and replace on
need basis
vii) Pins & Cotters. – check and replace on need
basis
1.3.5 Wheel sets and CTRB’s are attended as per para 1.2.2 (g)
1.3.6 CBC and DG are attended as per para 1.2.2 (f)
1.3.7 Air brake system is attended as per para 1.2.2. (d)
1.3.8 Welding preparation:
a) The surface to be welded should be cleaned properly to
remove dust , oil, cracks, scales preferably by grinding with
portable grinder
b) All welding shall be carried out in down hand position with the
help of manipulator whenever required.
c) Low hydrogen electrodes approved by RDSO shall be used.
d) For welding of liners start from one corner and then weld
opposite corner and so on till four corners are completed in
the same pass.
e) Electrodes shall be pre heated in a drying oven at
temperature of 150-200oC at least one hour before use.
f) No post weld heat treatment is necessary.
g) Reconditioned area shall be examined visually as well as by
DTP to ensure freedom from any defect / cracks.
1.3.9 ASSEMBLY:
a) Lower the under frame on bogie provide pivot pin shackle, pin
with split pin and connect brake gear pin. Dimension-60
between CP top to side bearer top liner should be maintained.
b) Check distance of side frame top liner to side bearer keep
distance within tolerance (131 +0, -0.5) by altering.
c) Ensure all APD measure are incorporated after assembly.
d) Paint bogie, stencil station code and date of ROH.
e) Draw bar height and CBC height should not be more than 845
mm and 1105 mm respectively. No packing should be given
over axle box adapter.
f) Check proper fitment operation of twist lock for proper locking.

Page 14 of 36 Quality Audit of Wagon Depot

 SN Requirements Clause Observations
1.3.10 After assembly and completion of finishing work, carry out air brake
testing with SWTR

Check point Specified

i). BP Pressure 5 ± 0.1kg/cm2
ii). AUX. Reservior Pressure 5 ± 0.1kg/cm2
iii) Leakage from system after charging 0.1kg/cm2 in
one minute
iv) Full service and emergency application 18 to 30 seconds
cylinder filling time
v). Maximum brake cylinder pressure Empty 2.2 ±
0.25 kg/cm2
Loaded 3.8 ± 0.1
kg/cm2
vi). Reduction in BP Pressure required for 1.3 to 1.6 kg/cm2
full service application
vii). Release after full service 45 to 60 seconds
viii). Sensitivity of brakes. Isolate brake Brake should
from mail line. Check response of brakes apply within 6
when BP Pressure is reduced to 0.6 seconds.
kg/cm2 in 6 seconds.
ix). Insensitivity of brakes. Isolate brake Brake should not
pipe from mail line. Check response of apply
brakes when BP Pressure reduced to 0.3
kg/cm2 in 60 seconds
x). Piston stroke Empty 85 ± 10
mm
Loaded 120 ± 10

Page 15 of 36 Quality Audit of Wagon Depot

 INFRASTRUCTURAL FACILITIES IN ROH DEPOTS
(Ref: Appendix –II of CAMTECH Wagon manual)
A) Depot Name: GIM wagon depot

B) Category of depot:

Category Targeted capacity for Status of Depot

ROH (Average/month) (Av ROH attention per
month in VU during last
one year)
Super Depots Above 500 Major Depot with monthly Target
Mega Depots 250 to 500 220 VU
Major Depots 125 to 250 Last One year
Minor Depots Upto 125

C) Covered area under cranes: The recommended cranage area for depots undertaking 250 to 500 ROHs per month is given
below:

1. For ROH depots WITH sick-line attention:

Requirements Observations
250 ROHs/month + sick line repairs with double shift. 5000 sq. m including
wheel lathe shed
300 ROHs/month + sick 5600 sq. m
350 line repairs with 6200 sq. m. Not applicable
double shift.
400 6800 sq. m
450 7400 sq. m
500 8000 sq. m

2. For ROH depots WITHOUT sick-line attention:

Requirements Observations
Depots undertaking only ROH workload and no out-of-course Not Applicable
repairs can manage the outturn of 250 ROHs/month in about 3000
sq. m. cranage area with working in double shifts.

D) M&P requirement:

Recommended list of M&P for a unit depot i.e. handling 250 ROH per month as per CAMTECH wagon manual. For a
depot handling more than 250 ROH per month, the requirement has to be scaled up depending on depot layout and
facilities created. Requirement of M&P for each section is given below:

Page 16 of 36 Quality Audit of Wagon Depot

1. Body section

SN M&P Quantity Observations

1 EOT cranes 15t/5t 2 Nos 02 Available of 15/5T
capacity
2 Welding machines 4 Nos 04 Available
3 Portable hydraulic rivetter 1 No Pneumatic hydraulic
riveting hammer is
available
4 Trestles 12 sets 10 Sets Available
5 PC terminal (common with bogie No. will depend Available
section if layout permits) on layout
6 Portable Winches As per layout Not Available
7 Grit Blasting Machine 1 No. Not Available

2. Bogie section
SN M&P Quantity Observations
1 EOT crane 10t / 3t 2 Nos 02 Available of 15/5T
capacity
2 Welding machines 6 Nos Available
3 Portable hydraulic rivetter 1 Nos Available
4 Stores bin 20 Nos Available
5 Portable electric griders 3 Nos. Available
6 Jib crane 2.5t 10 Nos. Not Available
7 Fixture for rivetting spring plank 2 Nos. Available
8 Work station for bogie repair 10 Nos. Available
9 Turn table for wheel sets As per layout 01 No. available
10 Road crane 10t capacity 1 No Not Available
11 Bogie manipulators 3 Nos. 02 Nos Available
12 Roller bearing diagnostic equipment 2 Nos. Not available
13 Magnetic flaw detector 2 Nos. Not in use
14 CO2 welding machine 2 Nos. Co2 available

3. Air brake equipment

SN M&P Quantity Observations

1 Elec. Stationery screw air compressors complete with 1 No. Available 500 CFM
air receiver 15 m 3/min (This is for depot only.
Additional compressors will be required for yard).
2 Portable diesel compressor 1 No. Not Available
3 Single Wagon test rig 2 Nos. 03 Nos Available
4 DV test stand 1 No Available but not in use
5 Hydraulic pipe bending machine 1 No. Available
6 Air conditioners with voltage stabilizer 2 Nos. Not Available
7 Torque wrench with various sizes of sockets less 4 set. Available
than 1 inch
8 Ultrasonic cleaning table for DV components 1 Nos. Not Available

4. Wheel Reconditioning Equipment

SN M&P Quantity Observations
1 Surface wheel lathe with Servo controlled voltage 1 No. Available
stabilizer
2 Pneumatic torque wrench with sockets 1” to 2” 4 sets 1 set Available
3 Pressure grease drum with guns 15t capacity. 2 Nos. Not Available
4 Ultrasonic flaw detector 2 Nos Available

Page 17 of 36 Quality Audit of Wagon Depot

 5 Bearing marking gadget 1 set Manual punch kit
6 Mono-rail for handling swarf (detail plan will depend on 1 set Not Available
layout)

7 7 Bins for storing bearings As per Available

requirement

8 Fork lifter 2.5t 1 No. Available

9 P.C. Terminal 1 No. Available
10 Wheel diameter measuring gauge 2 Nos. Available

5. Machine shop & material reclamation

SN M&P Quantity Observations

1 Heavy duty shaping machine 1 No Not Available
2 Jib crane 2.5t 1 No Not Available
3 Centre lathe 12 ½” cap. 1 No. Not Available
4 Redial drilling machine 1 No. Not Available
5 Centre lathe 6” cap 1 No. Not Available
6 Bench drilling machine 1 No. Available
7 Heavy duty pedestal grinder double ended 1 No. Available
8 Shearing machine 6 mm 1 No. Available

6. Stores

SN M&P Quantity Observations

1 Truck 10t capacity 1 No. 1 Available 9 T Cap
2 Tractor with hydraulic lifting machine and 3 trolleys 1 No. Not Available
(trailers)
3 Fork lift 2t 2 No. Available
4 Platform truck 2t 2 Nos. Available only for yard use
5 Battery charger 2 No. Not available
6 Weighing machine 500 kg 1 No. Available
7 Light store vehicle 1 No. 2 No. Available
8 Hand trolleys with rubber wheels 10 Nos. Availalbe
9 Storage racks As per layout Available
10 Computer terminal with printer 1 No. Available
11 Furniture As per layout Available

7. Black smithy

SN M&P Qunatity Observations

1 Black smithy hearth 1 No. Not in use
2 Anvil 1 No. Available
3 Hand tools 5 sets Available
4 Motorised blower 1 No. Available

Page 18 of 36 Quality Audit of Wagon Depot

 8. Training equipment

SN M&P Quantity Observations

1 Cut models of DV, SAB, Angle cock. 1 No. of each Not Available
design
2 Television (large screen) projector type 1 No. Available 1 PC
3 VCR 1 No. Not Available
4 Furniture As per layout Available
5 Hostel along with kitchen equipment Not Available
6 Overhead projector 1 No. Available
7 LCD projector 1 No Not Available

9. Canteen & staff amenities

SN M&P Quantity Observations

1 Water cooler 13 No. 01 No. Available
2 Stainless steel tables & chairs As per reqt. Available
3 Kitchen equipment, cooking gas, utensils As per reqt. Available
4 Fitter’s lockers As per reqt. Available

10. Office Equipment

SN M&P Quantity Observations

1 PC terminal 2 No. Available
2 Printer 1 No. Available
3 Furniture As per layout Available
4 Air conditioner for DME’s chamber & computer room. 3 No. Available 1 In DME Sir
Chamber
5 Intercom 10 lines 1 No. Not Available
6 Fax with P&T line 1 No. Not Available
7 First aid equipment 4 set Available 03 Set
8 Photocopier 1 No. Available
9 V.H.F. sets. 10 sets Not Available

11. Miscellaneous

SN M&P Quantity Observations

1 Gas cutting equipment 4 Nos. Available
2 Hydraulic jacks As per requt Available
3 SAB test bench 1 No. Not Available
4 CBC and draft gear replacement equipment 1 No. Available
5 DG set 350/500 KVA 1 No. Available
6 Lumpsum for electric and pneumatic tools Available
7 Lumpsum for fitter’s hand tools. Available
8 Lumpsum for gauges & instruments Available
9 Wheel flat detector system * Not Available (Tyre defect
gauge available)
10 Wheel flange welding machine * Not Available

(*) To be installed in depots/yards as per instructions of Railway Board.

12. Where power failures are rampant, a Diesel Generating Set to run the wheel lathe and cranes may also be planned.

Page 19 of 36 Quality Audit of Wagon Depot

 Quality Assurance Directorate (Mechanical)
RDSO Lucknow
Quality audit check-sheet for Yard attention (Intensive examination) and
sick-line attention of air brake freight stock
(Based on CAMTECH Maintenance Manual for Wagon and CAMTECH report on
Standardization of Infrastructure Facilities for Freight stock maintenance)
SN Requirements Clause Observations
1 Railway is following comprehensive instructions regarding RB letter no. Close Circuit Rakes - BCNHL,BCN,BOXN
the pattern of freight train examination and issue of brake 94/M(N)/ Premium – BCN, BOXN,BOXNHL,BOST
power certificate issued by Railway Board. 951/57/Vol II/Pt Intensive – BTPGLN,BOBYN, CC of other
dtd 25.10.04
railway
1.1 Zonal Railways should issue a detailed joint inspection RB letter no. 78 Issued time to time By ZR
for C&W examination for freight train in terms of RB / M(W)/814/8
guidelines by Operating and Mechanical department Vol.II dtd
every year in line with changes in traffic pattern 01.10.80 and
91/
M(N)/951/31
dtd 24.03.95
2 Intensive examination of different stock: Para 303 of
a) All freight trains should be subjected to intensive CAMTECH Followed as wagon Manual
examination in empty condition at originating station. Wagon manual
b) In exceptional cases, the back loaded freight train Not examined
can be examined as per instruction mentioned in
para 314 item (v) of CAMTECH Wagon manual.
c) All freight trains shall be re-examined if stabled for Intensive examination done as per wagon manual
more than 24 hrs by JE (C&W) in yard and by Guard
and Driver in non C&W station up to next C&W point
in the direction of movement for examination.
d) Air brake stock should run on end to end pattern /
premium / CC pattern. The intensive BPC shall
remain valid provided:
 The destination is clearly mentioned on the Feeding by Operating Dept.
BPC of loaded train.
 The composition of rake is not changed by 4 or Followed as per wagon manual
more wagons (5 or more wagon for BLC rake.)
3 Premium examination of air brake freight train : RB letter no.
a) Premium rakes will be intensively examined in 2005/M(N)/ A Category Yard, Examination as per wagon
empty condition and certified by examination point 951/13 dtd manual
nominated by CME & COM. Such premium 07.04.06
examination point should be “A” category” or should
be upgraded to ‘A’ category.
b) If any of the condition i.e. examination in empty NA
condition or examination at nominated point is not
satisfied then rake will operate normal end to end
rake.
c) BPC issued for such premium rake will be valid for
12 days from the date of issue (Grace period of 3 12+3 days premium BPC issued BCN,
days for unloading and to avoid examination in BOXN,BOXNHL,BOST,BRN
loaded condition)
d) After each loading / unloading, the rake will be Rake examined as per wagon manual
examined by Guard and driver before
commencement of journey and recorded under the
relevant column of BPC. In case of mechanized
loading / Unloading, examination by TXR is
desirable.
e) Premium rake should be turned out with 95% Brake
Power. BPC issued above 95%

Page 20 of 36 Quality Audit of Wagon Depot

SN Requirements Clause Observations
f) Movement of premium rake is monitored through Monitored by FOIS
FIOS.
3.1 All points nominated for premium examination of trains RB letter no. Followed as per mentioned letter
shall issue premium intensive BPC and such rakes will be 2005/M(N)/
formed by all type of air brake freight rolling stock except 951/13 / Pt dtd
BRN, BTPGLN, BLC, BFKN & departmental stock. 31.01.07
BLC rake will be examined on CC basis.
4.0 Close Circuit pattern of examination:
4.1 BOXNHL and BCNHL rakes are examined on CC RB letter no.
pattern with the following condition: 2008/M(N)/
 CC rake of BOXNHL and BCNHL will have validity 951/31 CC Only BCNHL CC rakes in GIM Yard as per
of 7500 Km/ 35 days. Rakes dtd wagon manual Named TORAL
 Rakes are examined at nominated point. During CC 11.03.10 Followed as per manual
examination, proper attention to the safety fittings
shall be given and their maintenance records shall Nominated lines for CC, Intensive,
be maintained separately.
examination with OHE. Only line No. 04
 CC examination will be done only at examination
lines in the yard having proper facility of material having no OHE.
handling, concrete pathway, welding, lighting etc.
The CC examination will be done lines on which
there is no OHE.
 CC rake is monitored through FOIS. In case CC Monitored by FOIS
rake is not mad available for examination at the
base depot and offered for examination at some
other depot, it will become non CC rake and it will
follow the normal intensive examination pattern.
 After each loading/unloading, the rake will be Done by guard and driver
examined by Guard and Driver and observations
recorded on BPC. Record kept and maintained
 Detail record should be kept for the performance of
the rakes and their condition should be recorded
during every examination.
4.2 CC examination of other air brake freight stock: RB letter no.
 The air brake CC rake shall be offered for periodical 94/M(N)/ Followed
maintenance examination (PME) in empty condition 951/57/Vol II/Pt
at the CC depot that formed CC rake originally. dtd 25.10.04
 Rake integrity as listed in BPC should be and para 303 of Followed
maintained. However, upto 4 wagons (for BLC rake CAMTECH
– 5 wagons) may be replaced by good, examined Wagon manual.
wagons in the entire run between two PMEs.
 The KMs have been logged in correctly and Done
continuously.
 The rake is not stabled for more than 24 hrs. Done (if stable more than 24 hrs then intensive
 The rake is running in predefined circuit as examination)
mentioned in BPC.
 After each loading/unloading, the rake will be Done by Guard and Driver
examined by Guard and Driver and observations
recorded on BPC.
 All CC freight trains will be given intensive Followed
examination during day light hours.
 BPC of CC rake is valid for 7500 km / 35 days for ‘A’ Only 7500 Kms/30+5 Days
category points (as notified) and 6000 km/30 days
for other examination point as per JPO issued by
Zonal Railways.
 POH / ROH wagons from CC rakes will be marked Detached only at Base Depot
and detached at base depots only.
 CC rake should be preferably formed by off ROH / Followed as per manual
POH wagons
4.2.1 BOXN / BCN CC rakes are to be formed at nominated RB letter no. No any BOXN/BCN CC rake base of GIM
examination points. 2008/M(N)/
951/13/CC

Page 21 of 36 Quality Audit of Wagon Depot

SN Requirements Clause Observations
rakes dtd
28.10.09
4.2.2 BTPN CC rakes are to be formed at nominated RB letter no. Not Done, Yard not Nominated
examination points 2008/M(N)/ for BTPN
951/13/CC
rakes dtd
05.02.10 &
13.07.10
5.0 Attention to be given during intensive examination
(CC/ premium / end to end):
5.1 Adequate gang strength is deployed for intensive Para 313 of
examination: CAMTECH
Air brake (end to end): 56 man-hour Wagon manual Followed
Air brake (CC): 100 man-hour Followed
Premium rake: 66 man-hour CAMTECH Followed
letter no.
IR/CAMTECH.
M.
GWL.Premium
Fr
Dtd 29.05.09
5.2 Rolling-in examination including axle box feeling: Para 305A of
 All terminating trains should be given rolling-in CAMTECH Being Done as per Manual.
examination while entering a Station / Yard with a Wagon manual.
train examination depot.
 The following inspection should be carried during Done
the rolling –in examination:
 In motion inspection and observation of under
gear of wagons for any loose or dangling Done
components and flat places on tyres / wheels
 After train has come to halt, all boxes should Unsafe wagon marked sick by axle box feeling
be felt within 20 mts. staff
 Examination of any abnormal behaviour of any
of the vehicles or any other observation Followed
which may relate to unsafe working condition.
 The rolling –in examination must be conducted Collected with train advise
to detect any skidded wheel.
 In-coming BPC should be collected by Yard
C&W staff.
5.2 Intensive examination and repairs: Para 305 B of Protected by danger board wooden wedge and
Before undertaking intensive examination, the rake CAMTECH scotch block
should be protected at both the ends. The following Wagon manual
examination and repair activities should be carried out:
 Inspection and repairs of running gear fittings. Done
 Inspection and repairs of brake gear and spring Done
gears.
 Inspection and repairs of draw and buffing gear. Inspected and marked sick as per rejection rules
 Checking and making good the deficiency of safety
fittings, safety bracket, safety loop etc.
 Replacement of brake block on condition basis. Followed
 Correct fitment of washers, bulb cotters and all Followed
brake gear pins to be ensured.
 Correct functioning and positioning of empty load Followed
device.
 Wagon with warm axle box to be detached and Detached and checked at sickline
may be taken in sick line for further action.
 Checking and proper securing doors. Done
 Observe CBC height, wear plate , Knuckle etc by Followed
visual examination. In case of doubt, buffer height
should be measured.

Page 22 of 36 Quality Audit of Wagon Depot

SN Requirements Clause Observations
 Check brake cylinders, DV, AR, CR and other pipe Followed
joints to ensure that these are in proper working
order. Isolating cock and angle cock to be checked
for proper position. Brake cylinder should be
released and checked for piston stroke for empty
and loaded condition.
 After brakes are released, the wheel profile should Followed
be examined visually. If any defect is noticed, it
should be checked with tyre defect gauge and
wagon to be marked sick for wheel changing. Followed
 The bogies complete side frames and bolster to be
visually examined for cracks and missing parts,
bolster springs, snubber, spigot, centre pivot
fastening etc to be checked for defects and
attended.
 Examine brake rigging components with special Followed
attention to brake beam deformation and wear on
integral brake shoe bracket. Check puul rod, push
rod with pins, washers, split pins and cotters.
 Hand brake must be checked for smooth and
effective operation. Followed
 Visual examination of under-frame members, body,
door mechanism, CBC wear or deficiency of parts Followed
to be marked and their operation to be checked.
 Brake power should be ensured. (CC – 100%, Ensured during BPC issuing
Premium end to end – 95 % and end to end
examination – 90 %)
 Where a reject-able defect cannot be attended in
Yard, the wagon shall be damaged for attention in Marked sick for further attention
sick line.
5.3 Issue of Brake Power Certificate: Para 305 C of
 All freight trains after intensive examination will be CAMTECH Issued through FMM
given a Brake Power certificate. wagon manual.
 BPC certificate should be printed in different colour
on good quality paper: FMM generated print issued.
 CC rake – Yellow colour.
 Premium rake – Green colour
 Air brake end to end – Green colour.
 BPC should be issued in standard format.
 Originating brake power for air brake rake in CC
Ensured through FMM
shall be 100% Followed
 Originating brake power for premium air brake rake Followed
shall be minimum 95%
 The minimum brake power for air brake freight
Followed
train on end to end pattern shall be 90%.
 No fresh BPC shall be issued during re-validation. Followed
 No safe to run BPC issued from nodal point. Not done
 Brake pipe pressure in air brake train with
locomotive should be as follows: Followed as per standard
Nos of wagons On On last
locomotive wagon
Upto 56 5.0 Kg/Cm2 4.8
Kg/Cm2
Beyond 56 5.0 Kg/Cm2 4.7
Kg/Cm2

5.4 Important parameters to be ensured during intensive Para 307 of

examination: CAMTECH
wagon manual

Page 23 of 36 Quality Audit of Wagon Depot

SN Requirements Clause Observations
5.4.1 Brake gear limit and clearances:
Description Limit
Brake block cond limit 10 mm Followed and maintained clearances
Yard leaving thickness of brake 20 mm
block except BOY
A dimension of air brake stock fitted 70 mm
with CASNUB bogie except BOBRN +2
-0
A dimension of BOBRN wagons 27 mm
+2
-0
5.4.2 Piston stroke:
Types of wagon Piston stroke
Empty Loaded
BOXN, BCN, 85 mm +/- 130 mm +/-
BRN, BTPGLN 10 10
Maintained
BTPN 87 mm +/- 117 mm +/- NA
10 10
BOY 90 mm +/- 135 mm +/- NA
10 10
BOBRN/ 100 mm +/- 110 mm +/-
BOBR 10 10
NA

5.4.3 Buffer Height from Rail Level: Followed

 Maximum 1105 mm (Empty)

 Minimum 1030 mm (Loaded)
6.0 Important parameters to be ensured during Sick line / Para 308 of
Depot attention: CAMTECH
wagon manual
6.1 Nominal clearances of CASNUB bogie: Para 308 C of
CAMTECH
Description 22NLB 22 HS wagon manual
Lateral clearance between 18 mm 25 mm
side frame and bolster
Checked and maintained
Lateral clearance between 16 mm 16 mm
side frame and axle
box/adopter
Longitudinal clearance 9 mm 9 mm
between side frame and
axle box / adopter
Longitudinal clearance 6 mm 6 mm
between side frame and
bolster
Clearance between anti 4 mm 4 mm
rotation lug and bolster

Page 24 of 36 Quality Audit of Wagon Depot

SN Requirements Clause Observations
6.2 Wear limits Para 308 D of
Adapter thrust shoulder 0.7 mm CAMTECH
Adapter crown lugs 4.0 mm wagon manual Followed
Adapter crown seat 3.5 mm
Adapter side lugs 3.0 mm
Adapter sides 3.0 mm
Side frame column friction plate 4.0 mm
Side frame column sides 5.0 mm
Side frame anti rotation lug 3.0 mm
Pedestal crown roof 5.0 mm
Pedestal crown sides 4.0 mm
Pedestal sides 2.0 mm
Pedestal jaw 4.0 mm
Bolster liner wear limit 5.0 mm
Bolster land surface 3.0 mm
Bolster column sides – Inner / outer 5.0 mm

6.3 Free height and condemning limit for CASNUB bogie Para 308 E of Followed
springs (Outer, Inner and Snubber) are maintained as CAMTECH
recommended in para 308 E wagon manual
6.4 Wear limit for Friction wedge is maintained as Para 308 F of
recommended CAMTECH Followed
wagon manual
6.5 Centre pivot dimension is checked as recommended Para 308 G of
CAMTECH Checked
wagon manual
6.6 Wheels and axles are checked for condemning diameter Para 308 I of
CAMTECH Checked
wagon manual
7.0 Air brake testing facility: Ch 3 of
i) Compressor of adequate capacity to carry out air CAMTECH
brake examinations of rake during intensive Manual for 02 Nos Available – 01 electric of 300 CFM & 01
examination as well as air brake testing of wagon in Wagon Diesel of 300 CF
sick line . Pneumatic line is provided with moisture
trap or air-dryer to ensure availability of moisture
free air for air brake testing.
ii) Availability of adequate RTR for air brake testing
during intensive examination and SWTR for air 01 Manual & 03 computerised RTR available and
brake testing in sick line. 01 Manual SWTR in sick line
8.0 Infrastructure facility for Yard maintenance Ch 3 of
i) Adequate centre to centre distance between tracks CAMTECH Total 06 intensive examination lines available. In
(at least 7..5 mts) for conducting intensive Manual for which old line 1, New line 3 & new line 04
examination. Wagon having 7.5 mtrs track center distance available.
Old line 2,3 & 4 having not 7.5 mtrs track center
ii) Concrete pathway from one end to other end. CAMTECH distance.
Material handling facility to ensure movement of report on Available in all intensive line except old line 04
material from one end to other end. Standardisation east side.
iii) Proper illumination for conducting intensive of Infrastructure
examination. facilities for LED street light available
iv) Welding facility (Rectifier type) for welding during freight stock
intensive examination. maintenance Available
v) Adequate outlets for tapping air pressure for testing CAMTECH /
of stock. 2003/M/NF- Available
vi) Duty room for maintenance supervisor, compressor STD
room, store room, tool room, welding machine Aug 2003 Available
room for intensive examination.
vii) VHF sets for close monitoring. Available
Infrastructure facilities for Yard attention to be verified as
per Checklist (Annexure-I) of CAMTECH guidelines for
Standardization of Infrastructure facilities for freight Not available.
stock maintenane
Page 25 of 36 Quality Audit of Wagon Depot
SN Requirements Clause Observations
9 Sick line facilities: Infrastructure facilities should be CAMTECH
available as per Table II of CAMTECH guidelines for report on 1 covered shed with 78x12 m with 25/5 t EOT
Standardization of Infrastructure facilities for freight stock Standardisation crane with 4 nos. maintenance lines with total
maintenance of Infrastructure holding cap of 87 BG wagons
facilities for
freight stock
maintenance
CAMTECH /
2003/M/NF-
STD
Aug 2003
10 Analysis of sick marking and yard attention is being - Analysis being done manually and record keeping
carried out. Computer facility for such analysis is done with computer
available.
11 General housekeeping:
Level of Housekeeping Satisfactory
Overall ambience and working condition Satisfactory
Storage of Wheel sets 70 wheel set storage available
Storage of Air brake cylinder, BMBS, AR and other Available
stores.

12.0 Miscellaneous items for attention as advised by RB

12.1 Corrective and preventive measure to detect hot axle RB letter no.
box cases (potential case of train accident due hot 2005/M(N)/951/
axle breakage) 49 dtd 05.10.11 Axle box feeling staff checks all incoming rakes
 Alertness of TXR staff on platforms, station staff,
gateman, signal maintainers etc for detecting hot
axle box case and taking necessary corrective Available
action.
 Safety poster depicting hot box detection and
immediate follow up should be affixed at all stations, Followed by axle box staff
gate huts, cabins and maintenance depot.
 Ensure practice of box feeling immediately on arrival
of train in examination yard. Measure axle box Followed
temperature with non-contact measuring
temperature instrument. Reports send to RDSO for analysis by division
 Care should be taken at wagon depot while handling
wheel sets to avoid any damage to grease seals.
 All cases of hot BOX must be investigated and a
detailed report must be submitted to RDSO.
12.2 Attention for non –functional hand brake: RB letter no.
 RB has advised Railway to take immediate 2012/M(Safety)/ Followed
remedial measure to make good non-functional 10/ Misc
hand brake. Inspection dtd
 Action taken by Railway for detecting non 05.10.11
functional hand brake and making good deficiency Followed
in Workshop, ROH depot, Sick-lines and Yard.

12.3 Action taken by Railway on the basis of CRS/NE’s RB letter no.

circle final report: 2012/M(Safety)/
 Para 9.1.1 of CRS report: Railway should carry out 7/1 NCR-II dtd Followed during ROH and sick line
a drive to check the fitment of hand brake wheel 24.05.12
and its spindle on the wagons. Riveting of spindle attention
with sleeves should be done wherever deficient in
accordance with RDSO drg no. WD – 09056 – S -
07.
 Para 9.1.2 of CRS report: In addition to riveting,
welding of spindle with sleeve should also be
Followed
considered as this item is said to be prone to theft.

Page 26 of 36 Quality Audit of Wagon Depot

SN Requirements Clause Observations
12.4 Fire prevention in BTPN wagon: RB letter no. NA
Implementation of RDSO guidelines circulated vide letter 2005/M(N)/951/
no MW/BTPN dtd 22.06.12 for fire prevention in BTPN 41 dtd 26.06.12
wagon
12.5 Inspection of depot by Officers / Supervisors RB letter no.
 Inspection of freight depot (sick-line, Yard and ROH 2009 /
depot) is carried out as per RB guidelines: M(safety)/7/2/C
Type of inspection JA SS JS Sup hecklist –
Sick-line 1 2 2 2 inspection dtd Followed
Yard 2 2 3 3 9.09.09
ROH depot 1 1 1 1
Super check of 1 2 4 4
goods rake
Night inspection 1 1 1 2
Office inspection 1 1 1 1
Brake Power Check
(Goods Train)
Qualities of GDR 1 1 2 4
check

 Items during freight examination as per above

schedule are checked as per guidelines laid down Checked
vide RB letter no. 2009 / M(safety)/7/2/Checklist –
inspection dtd 9.09.09

Page 27 of 36 Quality Audit of Wagon Depot

 Annexure-I
CHECKLIST FOR FREIGHT STOCK EXAMINATION POINT
(Ref: CAMTECH guidelines for Standardization of Infrastructure facilities for freight stock maintenance)

Railway: WR Type of stock: BCNHL, BCN, BOXN, BOXNHL , BOST, BRN

Type of attention CC, Pre mium, En d-to-End
Division: ADI (GIM) Avg. no. of rakes examined: 200 per month in FY 23-24
Availability
SN Item Remarks
Yes No
1 7.5 m center to center distance between two lines No Adequate distance not available in
old line 2,3 & 04
2 Concrete path way Yes
3 Paved road for truck movement No Available only for reaching to yard
4 Supervisors Room Yes
5 Staff room Yes
6 Rolling in/out huts No Only rolling lights available but no
hut for staff
7 Field store + Tool room Yes
8 Compressor Room Yes
9 Exhauster room Yes
10 Battery Charging room No Compressor room shed available.
11 Tower light Yes
12 Street light along examination lines at two levels Yes
13 Portable rechargeable light Yes
14 Hand lamps Yes
15 Welding line Yes
16 Arc welding set (Mounted on trolley) No Not available
17 Portable DG set No Not available
18 DG set 250 KVA (for compressor, light and welding) No Available for sick line and yard use 350
kva cap installed at sickline
19 Electric Compressor (500 CFM) Yes 300 CFM available
20 Diesel Compressor (500 CFM) Yes 300 CFM available
21 Exhauster Yes
22 Gas cutting set Yes
23 Hyd. Cold cutting set/Hand shears Yes Available at sick line
24 Protective clothing with Helmet & Cloves Yes
25 Welding apron & welding glass Yes
26 Pneumatic pipe line (32 mm dia) Yes
27 Rake test rig Yes
28 Hydraulic jacks Yes
29 Wheel barrow Yes
30 Pick up van Yes
31 Truck Yes Available in store
32 Lister truck Yes
33 Road mobile crane No Not available
34 Hand trolley Yes
35 Portable drill machine 12 mm No
36 Drill machine No
37 Bending machine No
38 Fitter tool box Yes
39 Pressure gauge test stand Yes Available in T&P store
40 Folding type portable wheel diameter gauge No
41 Rail profile gauge cum recorder in box No
42 Wheel distance measuring gauge No
43 Buffer height gauge Yes
44 Tyre defect gauge Yes
45 Electronic device/Infrared thermometer for detecting warm box Yes
46 Electric operated hand tools, i.e., Grinder No Not availalbe
47 Pocket jack (Hydraulic) 6 tons capacity Yes 20 T capacity jack available
48 Hand tools Yes
Page 28 of 36 Quality Audit of Wagon Depot
 Availability
SN Item Remarks
Yes No
49 Storage rack with pigeon holes Yes
50 Rack with locker Yes
51 Plain paper fax with P&T line No

52 Walkie Talkie set/Mobile phone Yes CUG sim provided to all employee
53 Railway Telephone Yes
54 BSNL Telephone No

55 Computer with printer, Scanner, UPS with preloaded software & modem Yes
56 C&W Office furniture Yes
57 Railnet / Internet connection Yes
58 Plain paper copier Yes
59 First aid equipment Yes

Page 29 of 36 Quality Audit of Wagon Depot

 Table II
Standard Infrastructural facilities
including M&P for Sick-line Maintenance of freight Stock
(Ref: CAMTECH guidelines for Standardization of Infrastructure facilities for freight stock maintenance)

Major Minor
SN Description (up to 250 FWU per month) Observations
(>250FWU per month)
A INFRASTRUCTURE
1 Covered shed 100mX75mX12m high 100mX75mX12m high Details of
Height of crane should be about Details of layout are shown layout are shown in sketch Major sick line with
10m so that wagon can be lifted in sketch covered shed 78m x12.5 m
by EOT crane and moved over
standing wagon to place
anywhere in the bay.
2 SAB repair room 5x16m 5 x16m Not Available
3 Air brake & vacuum brake rooms 5x20m Not Available
4 Service building (electrical rooms, 5x24m 5x12m Not available
staff room on both sides)
5 Computer room 5x8m 5x7m Available
6 Store room + sub store + tool 5x26m 5x15m Available
room
7 Machine shop 5x20m 5x8m Not Available
8 Battery room for charging 5x7m 5x3m Not available
lister/jumbo truck
9 Compressor room+ Exhauster 5x12m 5x9m Available
room
10 Office & SSE/SE/JE rooms 5x16m 5x5m Available
11 Sections for attention to various 5x44m 5x18m Not available
items as detailed in layout
12 Room for DG set At suitable location removed from main shed too contd. Noise Available
interference
13 Total lines required Six lines under covered Two lines under covered shed Total 4 lines with covered
shed and one line each out and one linie each out of covered shed of area975 sq m
of covered shed for wheels shed for wheel and turn around.
& turn around.
14 Pit line One pit 20m long (at one end only) on each line depth 960mm Not available
from rail level with adequate drainage.

15 Distance between two lines 10 meters 7.6 m avg

16 Pathway between the lines Heavy duty concrete Complete concrete
flooring work is in
progress
B LIGHTING
1 Tower light Six tower lights per sick line Four tower lights per sick line Not available
with adequate height with adequate height
2 Street light along examination One row per examination line covering both sides having proper Available
lines illumination specially covering bogies and brake gear locations.
The lights should be at two levers (lower lever for under gear and
upper lever for body)
3 Lighting in the shed and sections Refer to Annexure III on illumination Available
C MACHINERY & PLANT

1 EOT cranes 15T/5t 4 2 1 no 25/5 T capacity

2 EOT crane 10T/3T 2 - Not available
3 Road crane 10T capacity 1 1 Not available
4 Jib crane 2.5T 2 2 Not available
5 Electrical stationary screw air 2 1 1 Available (300 CFM)
compressor complete with air
receiver 15m3/Min (500CFM)
required for testing of air brake
Page 30 of 36 Quality Audit of Wagon Depot
 Major Minor
SN Description Observations
(>250FWU per month) (up to 250 FWU per month)
wagons.
6 Exhaust (required for testing of Not available
vacuum brake wagons)
7 Turn table for wheel sets As per lay out Not available
8 Trestles 12 sets 06 sets 4 sets
9 Hydraulic pipe bending machine 1 - Available
10 Heavy duty shaping machine 1 - Not Available
11 Centre lathe 12 1/2” capacity 1 - Not Available
12 Radial drilling machine 1 1 Not Available
13 Centre lathe 6” capacity 1 - Not Available
14 Bench drilling machine 1 1 Available
15 Heavy duty pedestal grinder 1 - Available
double ended
16 Shearing machine 6mmx2200mm 1 1 Available of 6 mm capacity
wide (required to make patches
for body work)
17 Battery charger (required for 1 1 Not Available
charging batteries of fork lifter
lister, truck and ot1h1er vehicles)
18 Weighing machine 500 kg (for 1 1 Available
scrap disposal)
19 DG set (required to run air 1 no.(500 KVA) 1no.(350 KVA) 1 Available ,320
compressor welding machine and KVAcapacity
for lighting in case of power
failure)
20 Gas cutting equipment 8 4 03 Available
21 Work station for bogie repair 10 1 Not available
22 Fixture for riveting spring plank 2 - Not Available
23 Welding machines 10 6 1 MIG, 2 oil
cooled,3
air cooled
24 Winches 3 1 Not Available
25 Bogie manipulators 3 - Not Available
26 Pipe line for air 32 mm dia As per layout Available
27 CO2 welding machine 2 - 1 Mig welding available
28 Rail cum road vehicle 1 - Not Available
29 Fork lifter 3T 4 1 01 Available
30 Truck 10T capacity 2 1 01 Available 09 T capacity
31 Tractor with hydraulic lifting 1 - Not Available
machine & 3 trolleys (trailers)
32 Platform, truck 2T 2 1 Not Available
33 Light store vehicle 1 1 Not Available
34 Hand trolleys with rubber wheels 10 6 Available
D TOOLS & EQUIPMENT
1 Portable hydraulic riveter 1 1 Available
2 Store bin 20 15 10 available
3 Portable electric grinder 3 2 Available
4 CBC & draft gear replacement 1 - Available
5 SAB test bench 1 - Not Available
6 Hydraulic jacks 15 t 8 7 nos,30 t capacity
7 Set of special spring spanners. 4sets 2sets Available per gang
Box spanners. Torque spanners 7set
8 Bottle jacks 8 3 Available
9 Pneumatic/electrical hand tools As per requirement Not Available
10 Gauges & instruments As per lay out Available
11 single wagon test rig 1 no. per 8 wagons per day 1 Available
12 DV test stand 2 1 Not Available
13 Hand tools As per requirement Available
Page 31 of 36 Quality Audit of Wagon Depot
14 Pneumatic torque wrench with 4 sets 2sets 1 set
sockets 1” to 2”
15 Ultrasonic leak detector for tank 1 1 NA
wagons
16 Pressure & vacuum gauge dead 2 1 NA
weight tester
E MISCLLEANEOUS
1 Water cooler 3 1 Available
2 Floor cleaning machine 2 1 Not Available
3 Fitter Lockers As per requirement Available
4 Fax with P&T line 1 - Not Available
5 Fast aid equipment 4sets 2sets Available
6 Photo copier 1 1 Available
7 VHF sets mobile phone 10sets 6sets Not Available
8 Storage racks As per requirement Available

Page 32 of 36 Quality Audit of Wagon Depot

 Quality audit check-sheet with regard to maintenance of
Stainless Steel Wagon (BOXNHL / BCNHL/BRN22.9)

(Based on Chapter 3 of CAMTECH Maintenance Manual for Wagon

And CAMTECH Guidelines for maintenance of Stainless Steel Wagons circulated vide
CAMTECH.M/W/SS/Wagon – 1.0 Dec’09 )

SN Requirements Clause Remarks

1.0 Facilities required for maintenance of Stainless Steel Wagons: Para 2.0 of
ROH CAMTECH
Freight
Sick line (200 guidelines One MIG/MAG at sick line and
Yard
SN Items (5 wagons for
(3 rakes / three in ROH available
Wagons/day) / maintenanceof
day)
Month) SS wagons
MIG/MAG
1 welding sets 02 Nos 02 Nos 03 Nos
(400 Amp) Six in yard ,six in sick line and
DC Arc
Welding eight in ROH arc welding
2 02 Nos 02 Nos 03 Nos
Rectifier machine available
(600 Amp)
Portable Air
Plasma
cutting
3 machine 02 Nos 02 Nos 03 Nos 3 in ROH 1 in sick line
(max
capacity 16 Available
mm)
Consumables
4 for air plasma As per requirement
M/s
Welding
electrodes
5 As per requirement Available
(Class D &
Class M2)
Huck Bolts of
6 As per requirement
various sizes
7
Lock bolts
2 sets 2 sets 3 Sets
Available
equipment
Portable Available
8 grinding 03 Nos 03 nso 05 Nos
machine)
SS wire 4 sets
9 As per requirement
brush
SS (IRS M44
10 As per requirement
plates) 4 nos

Available

Not Available

Page 33 of 36 Quality Audit of Wagon Depot

2.0 Equipment’s for Lock Bolt installation, air plasma cutting machine, DC Para 3 of
arc welding rectifier should be procured as per Specification laid down CAMTECH Equipment for lock bolt
in CAMTECH guidelines guidelines installation and Dc arc rectifierare
for
available
maintenance
of SS
wagons
3.0 Welders are qualified for welding of SS to SS and SS to Mild steel -do- Trained at BTC , Mumbai
4.0 Qualified personnel are available to carry out lock bolting, -do- Available
5.0 Sick line has facility for EOT cranes with covered area Ch 3 of Available, 25/5 t capacity
CAMTECH
Manual for
Wagon
6.0 Air brake testing facility: Ch 3 of
iii) Compressor of adequate capacity to carry out air brake CAMTECH 1 available 300 CFM in sick
examinations of rake during intensive examination as well as air Manual for line
brake testing of wagon in sick line . Pneumatic line is provided Wagon
with moisture trap or air-dryer to ensure availability of moisture 2 available in yard 300 CFM
free air for air brake testing. each
iv) Availability of adequate RTR for air brake testing during
intensive examination and SWTR for air brake testing in sick
line.
2 RTR in yard and 1 SWTR
for sick line and 2 SWTR in
ROH
7.0 Infrastructure facility for Yard maintenance Ch 3 of
viii) Adequate center to center distance between tracks (at least 7.5 CAMTECH Not Available
mts) for conducting intensive examination. Manual for
ix) Concrete pathway from one end to other end. Material handling Wagon Available
facility to ensure movement of material from one end to other
end.
Available
x) Proper illumination for conducting intensive examination.
xi) Welding facility (Rectifier type) for welding during intensive Available
examination.
xii) Adequate outlets for tapping air pressure for testing of stock. Available
xiii) Duty room for maintenance supervisor, compressor room, store
room, tool room, welding machine room for intensive Available
examination.
xiv) VHF sets for close monitoring. Not Available, cug provided for communication
Infrastructure facilities for Yard attention to be checked as per
Annexure – I of CAMTECH report for infrastructure facilities
8.0 Other facilities and M&P’s: Ch 3 of
i. Wheel diameter measuring gauge. CAMTECH Available
Available
ii. Wheel gauge. Manual for Available (Hired truck is available)
iii. Transportation facility for wheel sets and CTRBs. Wagon
iv. Availability of general tools for maintenance (Wrenches, Available
hammer, chisel, anvil etc).
v. Wheel defect gauge. Available
vi. Gauges for measuring ‘A” dimension & piston stroke. Available
vii. Electrodes heating chamber. Available
9.0 Analysis of sick marking and yard attention is being carried out. - Available
Computer facility for such analysis is available.
10.0 Supervisors and staffs are trained with regard to following: -
 Air brake testing of conventional BOXNHL / BCNHL stock as Supervisor and staff are trained
well as BOXNHL –MBS stock locally in GIM and BTC SBI
 Construction details of BOXNHL / BCNHL for yard examination
and attention as well as sick line attention.
 Huck bolting process for attention at Yard / Sick line.
 MIG / MAG welding process / MMAW welding process for SS
welding.
 Plasma cutting of SS sheets.
 Attention of BOXNHL / BCNHL door

Page 34 of 36 Quality Audit of Wagon Depot

11.0 Procurement of stores for maintenance of SS wagon
(BOXNHL/BCNHL)
i) List of stock items. Available
ii) List of non stock items. Available
iii) Storage facility with covered area for critical stores.
iv) Maintenance of ledger and consumption for last two years and Inadequate
current year.
Spares to be procured as stock items include items required for
Being maintained.
regular consumption of rolling stock.
12.0 General housekeeping:
- Level of housekeeping
- Overall ambience and working condition Satisfactory
- Storage of wheel sets
- Storage of air brake cylinder, BMBS, AR and other stores.

Page 35 of 36 Quality Audit of Wagon Depot

 Depot details

Depot name: GIM

Division and Railway: ADI/WR
Activities carried out:
SN Description Observations
1 ROH outturn per month (Av of last one year in VU) 220

2. 29 BCNHL CC Rake
Nos of CC rake running in service with brake up of formation (Rake type wise) Toral

3 Average examination per day (CC/ Premium/ end to end) CC -1.71

PREMIUM - 4.08
END TO END – 0.84
4
Average yard detachment per rake (Av of last one year) 4.42
4.1 In CC rake 5.72
4.2 In premium rake
4.30
4.3 In end to end examined rake
2.42
5.
Sick line outrun per month (Av of last one in VU) 928.14
6 Training of welders for MMAW / MIG welding
Trained
7 Training of staff in Oxy cutting
Trained
8 Training of staff in Plasma cutting
Trained
9 Availability of critical and safety stores Available
10 Whether a dedicated store officer is nominated for urgent procurement
Available
11 Sanctioned imprest value of depot officer
1.5 Lakh
12 Whether depot is ISO 9001 certified
Yes
13 Availability and display of work instruction in ROH depot /sick-line / yard
Available
14 Overdue refresher course of technician
Trained
15 Record keeping:

 ROH attention - Causes of replacement/rejection of components replaced/rejected Available

during ROH are to be recorded in a separate register. Assessment of monthly
consumption and trend of failure can be done by analyzing these records.
 Record for Yard attention with regard to manpower deployment, damage deficiency Available
register, consumption of stores etc.
 Record for sick-line attention stock-wise with man-hour utilization and consumption Available
of stores

Page 36 of 36 Quality Audit of Wagon Depot