VISION 2020 –For Mechanical Department of SECR
A vision document 2020 is prepared for Mechanical Department of SECR. The document outlines needs of the Mechanical Department in order to maintain different types of rolling stock to high level of availability, reliability and safety.
Due to increase in growth of passenger and freight traffic, there is need to plan for the future requirements of rolling stock for SECR including development of facilities and infrastructure for their maintenance in order to keep the rolling stock in good fettle. Accordingly, this vision document has been prepared considering 4 sections viz. Diesel Locos & DEMUs, Coaching, Freight and Workshops,MEMU.
2.0 DIESEL LOCOMOTIVES and DEMUS:
2.1 New Diesel Shed for 150 High Horse Power Locos:
New diesel shed is planned to be set up at Raipurto home 50 HHP locos. This shed will be further expanded to hold 150 HHP locos before 2020. It is planned that these locos shall visit new EMD shed Raipur once in 90 days and therefore could be of service anywhere in Indiain the interim period.
2.2 Modification in NG diesel shed, Motibagh for 50 HHP locos:
With the reduction in NG services due to gauge conversion, the requirement of NG diesel locos based at Motibagh diesel shed will reduce. The shed is being extended to accommodate 15 board gauge diesel locomotives. Thus the skill of the existing work force shall be utilized for maintenance of broad gauge HHP locos. By 2020, it is proposed that the shed will be further modified to home 50 HHP locos. It is planned that these locos shall visit Motibagh diesel shed once in 90 days and therefore could be of service anywhere in Indiain the interim period.
2.3 Additional DEMU rakes at Gondia –Total 20 rakes & additional shed:
Presently 7 DEMU rakes are based at Gondia. There are large number of main line coaching trains with short journey being used for commuter services. In order to release these coaches for overnight train journeys, about 20 additional rakes of DEMUs will be required over SECR. Hence planning needs to be done for additional infrastructure to home these rakes for maintenance. Also provision of storage facilities and material procurement planning needs to be done.
2.4 Conversion of NG passenger services to DEMU:
With gauge conversion in Nagpur region and Raipur region, there will be further requirement of DEMU services until the entire area is electrified. Presently the bare holding of main line coaches in SECR is inadequate in non-electrified section after gauge conversion from NG to BG.
2.5Bio-diesel –Deployment, stocking & use on locos.
A bio-diesel plant is being set up at Raipur by Indian Railway Organization for Alternate Fuels (IROAF). This is adjacent to new HHP diesel loco shed under construction. This will supply bio-diesel directly across the boundary wall to the fuel installation in the new HHP shed at Raipur. In addition, procurement of bio-diesel is done through Stores Orgn of SECR for 10% blending with fuel for diesel loco use. Due to depletion in natural fuel oil resources, it is essential to pursue the development and usage of bio-diesel further to approximately 15% blending with fuel.
2.6 New NG locos for maintaining NG service for next ten years till 2025.
As gauge conversion will take another 10 years due to paucity of funds in plan head, it is essential to keep the narrow gauge services in SECR operational for about 10 years. Therefore, it is essential that at least 5 new narrow gauge locos are manufactured under RSP due to aging of the fleet and codal life getting over of large number of locos.
2.7 AESS proposal in RSP:
To have control on fuel consumption, it will be useful to provide Automatic Engine Start & Shutdown (AESS) device in all the locos. It is expected that fuel consumption will come down by 5%. This needs to be planned for main line as well as shunting locos, as well as narrow gauge locos.
2.8Training centre for WDG4 locos:
With induction of HHP locomotives and phasing out of Alco locomotives, it is necessary that training is given at all levels to shed staff as well as running staff, on HHP loco systems, their functioning, maintenance, and operation. Provision of simulator in new EMD diesel shed and development of training modules for the same needs to be organized for LP/ALPs.
2.9140T brake down crane at Gevra Road:
With the construction of new lines from Gevra in 3 directions (East, West & North) these will be need for additional new 140 T brake down crane to be homed at Gevra Road. This 140T brake down crane should be planned for procurement before 2020.
2.10140 T brake down crane at Nainpur:
Due to vast gauge conversion of narrow gauge network in Nagpur division, a 140 T brake down crane will need to be based at Nainpur by 2025.
2.11Training centre for 140 T crane:
Brake down cranes of 140 T capacity involve new technology and thus one training centre needs to be developed in SECR in Bhilai area to educate staff on all aspects of theoretical and practical training in operation and maintenance of 140 T brake down crane.
2.12 Unit Exchange spares for locos:
We need to plan for unit exchange spares (UES) for HHP locomotives and DEMUs so that ineffective percentage targets can be reduced further and availability of HHP locos and DEMUs increased. The concept shall be that components, assemblies and subassemblies shall be replaced at the time of major schedule of locos and DEMUs so that such rolling stock can be released quickly for traffic use. The removed components shall be separately sent for maintenance without hold up of rolling stock from where it is removed. Likewise, adequate unit exchange spares of important components needs to be maintained for 140 T brake down cranes so that the reliability and availability of the same is effectiveness at times of accidents.
2.13Pit wheel lathe at Gondia for DEMU tyre turning. Presently, tyre turning of full DEMU rake is done at Bhilai Electric Loco shed as there is no in-situ tyre turning facility available for DEMU rakes. With the growth in the fleet of DEMU rakes, it is essential to have a under flow pit wheel lathe at Gondia, over which the whole DEMU can pass and tyre turning be done for the full rake.
3.1 Coaching terminals at Raigarh, Gondia, Korba Naya Raipur.
New trains are to be started from Raigarh, Gondia, Korba and Naya Raipur. Hence primary maintenance for these trains shall have to be done at new full-fledged coach maintenance depots at these stations. These are likely to home ICF type coaches. these terminals will need to cater to linen management through mechanized laundries and will require planning for mechanized cleaning of coaches at these depots as well as OBHS for the trains originating at these stations. Sick line and spare maintenance coach lines as well as lines for stabling of rakes after pit examination will also be required at these depots.
3.2 LHB coaching terminal at Uslapur/BSP:
About 80 LHB coaches shall be received at Bilaspur within two years. 12 coaches have already been arrived. It is essential to have a separate coach maintenance terminal for maintenance of LHB coaches. This can be planned in the land between Bilaspur goods shed and existing coach maintenance depot. These coaches will need to go to workshop for IOH as well as POH. Therefore, it is necessary to nominate workshops for these activities as presently there is no plan for developing workshop facilities for LHB in SECR.
3.3 Training centre for LHB coaches:
A training school can also be developed near the LHB coach maintenance terminal. This school shall be utilized to impart knowledge on design, construction, maintenance and operation of LHB coaches. It would be desirable to have cut section models for training purposes.
3.4 BOOT laundry of 6 T capacity:
At the present level of growth of passenger services as well as increase in number of coaches of existing trains, there will be at least 6% per year growth in number of coaches homed in SECR. Thus on today’s date, even with through departmental mechanized laundries at Bilaspur and Durg, each of 1 Ton capacity per shift, there is immediate requirement for a 6 Ton mechanized laundry on BOOT pattern to be commissioned in two years time at Bilaspur. Therefore, we need to process now and tender for the same in 2014 itself. This would take care of coaching services of Bilaspur division only. There will be additional demand for BOOT type laundry at NGP/SECR after gauge conversion.
3.5 NGP coaching depot:
After Narrow Gauge conversion to broad gauge, trains originating and terminating at Nagpur/SECR shall need primary and secondary maintenance as well as preventive maintenance schedules i.e. A, B, C for the coaches homed at Nagpur, SECR. There is already an existing coaching depot at Nagpur, CR and this is being shifted by Central Railway authorities to Ajni. Therefore, it can be planned that the existing coach maintenance depot at Nagpur Central Railway be taken over and developed by SECR for broad gauge coach maintenance after gauge conversion of Chindwara-Nagpur-Nagbhir line.
3.6 New NG coaches for maintaining NG service for next ten years till 2025.
As gauge conversion will take another 10 years due to paucity of funds in plan head, it is essential to keep the narrow gauge services in SECR operational for about 10 years. Therefore, it is essential that at least 20 new narrow gauge coaches are manufactured immediately under RSP due to aging of the fleet and codal life getting over of large number of coaches.
3.7 Unit Exchange spares for coaches:
We need to plan for unit exchange spares (UES) for coaches so that ineffective percentage targets can be reduced furthers and availability of coaches is increased. The concept shall be that components, assemblies and subassemblies shall be replaced at the time of major schedule of coaches so that such rolling stock can be released quickly for traffic use. The removed components shall be separately sent for maintenance without hold up of rolling stock from where it is removed.
4.0 Freight :
4.1Enhancement of ROH capacity:
The target of ROH for SECR has been enhanced in this financial year to 815 wagons per month. Out of this, the target for Bilaspur is 250 wagons and for PP yard Bhilai is 565 wagons per month. By the year 2020, it is planned to develop the infrastructure further for carrying ROH of 700 wagons per month at PP yard Bhilai and 400 wagons per month at BCN depot, Bilaspur. Material planning for stainless steel wagons (BOXNHL, BCNHL) as well as increase in budgetary provision for shift for maintenance from Mild Steel wagons to stainless steel wagons needs to be planned.
4.2Facilities for maintenance of 52 EUR rakes:
Railway Board has asked SECR to do primary maintenance of all EUR rakes of Indian Railways. Presently, the maintenance of existing 13 EUR rakes is done at BMY, Raipur division. Demand from Engineering Directorate of Railway Board is to develop a total of 52 EUR rakes at Bhilai for Engineering Deptt. of Indian Railways. Covered facilities will be required to be enhanced suitably at BMY. Furthermore, atleast two stabling lines and to more train examination lines will be required to be developed at BMY. This expenditure needs to be planned from PH -31.
4.3Unit Exchange spares for freight stock:
We need to plan for Unit Exchange Spares (UES) for freight stock including 52 EUR rakes so that ineffective percentage targets can be reduced further and availability is increased. The concept shall be that components, assemblies and subassemblies shall be replaced at the time of major schedule of freight stock so that such rolling stock can be released quickly for traffic use. The removed components shall be separately sent for maintenance without hold up of rolling stock from where it is removed. Material planning for maintenance of freight stock as well as increase in budgetary provision for these wagons needs to be planned.
4.4Freight examination facilities at Coal empty Yard, Bhilai:
3 lines have been laid at coal empty yard adjacent to PP yard. These lines shall be used for train examination due to the additional output expected from Bhilai Steel Plant. These three lines shall be commissioned very soon. It is expected that one train per shift shall be offered in this yard initially for CC examination (Primary maintenance examination). Hence, it is necessary to set up facilities including paved pathways between all the three lines for easy movement of men and materials. At least one gang of 8 staff in each shift for train examination needs to be created for this new activity. Suitable augmentation of EAC of materials as well as revenue budget for maintenance is required to be done.
4.5Premium examination facility at MXA:
Two lines are being laid at Marauda of Raipur division. Pathways need to be developed for examination of trains in these two lines. It is expected that one train per day shall be offered for premium examination at this new yard. At least one gang of 8 staff in day shift is required to be created for this new activity. Suitable material planning as well as budget provision for maintenance to be done, once this activity is started.
4.6Freight examination facility at DGG:
Due to increase in number of freight trains in SECR system as well as the expected increase in freight traffic due to gauge conversion in Nagpur division, it is necessary to develop freight examination facilities at Dongargarh. Earlier Railway Board had sanctioned development of facilities for freight examination at Gondia. However, operational constraints and change in pattern of traffic it has been desired by Operating Deptt. that the freight examination facilities be shifted to DGG. There is also shortage of lines at Gondia due to which this facility is required to be set up at DGG.
4.7Facilities for closing doors of BOBRN wagons at BRJN:
Presently empty BOBRN rakes are received at BRJN from BXQ and SEBD of ECoR via Jharsuguda road. These rakes cross both up and down lines and door closing is done at LJKR. Thereafter, they again cross both up and down lines for being placed at BOCM- 1,2,3,4,5. Thus complete train operation comes to a standstill on both main lines during such movements. It is, therefore, proposed to nominate one line for door closing activity in BOCM so that rakes from JSGR can come directly via up line to BOCM for door closing, without cutting across both up and down lines. Two pathways are required to be put on both sides of the nominated line each of width 2.5 metres so that mobile van can run on these pathways for movement of men and materials for closing doors as well as minor repairs to doors of BOBRN. This facility will result in increased line capacity.
4.8Rehabilitation of wagons at BMY –one thousand per year:
Facilities have been developed at BMY for midlife rehabilitation of BOXN wagons as well as for rebuilding of BOXN wagons. Approximately 700 wagons per year are being attended at BMY at present. Due to increase in the carrying capacity and wear and tear and damages to wagon sides and floor of large number of wagons, it is necessary to plan for rehabilitation of 1000 wagons per year. For this, additional funds will be required for contract work under PU -32 in revenue. Also it is necessary to strengthen contact management of these works at BMY.
5.1 Increased in POH capacity of WRS to 500 wagons p.m.:
Presently WRS/R is doing POH of about 276 wagons per month. It is seen that wagons are having very heavy damages and requires average of 600 man hours of work for POH. There is need to improve upon the infrastructure and productivity through mechanization in order to tackle the increased work load per wagon. Also there are 2 to 3 rakes waiting at Raipur at any time for POH. WRS/Raipur also does POH of wagons for ECoR. Railway Board has sanctioned the work for Augmentation of wagon POH capacity from 400 to 500 wagon per month in the year 2016-17. Work awarded to COFMOW on turnkey basis. Work is under progress. TDC-Dec 2021.
5.2 MIB WS BG coaching POH 70 p.m.:
Presently, there is no coaching workshop in SECR for doing POH of SECR coaches. Hence coaches of SECR are sent to Perumbur, Kharagpur, Hubli, Matunga etc. for POH. It is not only time consuming but also some coaches do not come back to SECR. Railway Board has sanctioned setting up of BG coach POH facilities at MIBW/NGP for doing POH of 27 non-AC coaches per month. Scope of work revised and present work may cater the requirement of 50 coaches per month and is alloted to COFMOW on Turn key basis in the year 2015. LOA issued to /s HYT in 2017. Work is under progress. TDC- Dec 2021.
5.3 POH facility for 20 DEMU rakes at Itwari/Kalumna:
Presently, DEMU rakes are sent to Perumbur and Charbagh for POH. This is time consuming and locomotives are required to take the rakes for POH to shops. As there will be increased in DEMU rakes homed in SECR. It is essential to develop POH facilities in SECR itself. Suitable site is Itwari or Kalumna.
5.4 Unit exchange spares for coaches, wagons, locos at workshops:
We need to plan for Unit Exchange Spares (UES) for coaches, wagons, locos at workshops so that ineffective percentage targets can be reduced further and availability of rolling stock is increased. The concept shall be that components, assemblies and subassemblies shall be replaced at the time of POH of rolling stock so that such rolling stock can be released quickly for traffic use. The removed components shall be separately sent for maintenance without hold up of rolling stock from where it is removed.
6.0 CONCLUSION :
The above are some thought by the author for developments on SECR, which will result in improved availability and reliability of rolling stock and will generate increased revenue in passenger and freight traffic.
7.1Vision Document 2020 on Indian Railways.
7.2Indian Railways Year Book 2011-12, for indication on projected growth.
7.3Annual Reports & Accounts 2011-12.
7.4Pink Book 2013-14, for new lines and Gauge Conversion.