|
CHAPTER 6 |
|
PERIODICAL REPAIR AND MAINTENANCE OF MACHINES |
Maintenance and repairs are essentially required for ensuring reliable and efficient working of track machines
6.2 Types of
Maintenance Schedules
Maintenance and repairs of machines shall be carried as per different schedules I to VII.
Details of the schedules are as under:-
|
Schedule |
Periodicity |
Duration |
Location |
|
Schedule - I |
Daily |
One hour |
In the field (Camp Coach) |
|
Schedule - II |
50 Engine hour |
Two hours |
- do - |
|
Schedule - III |
100 Engine hour |
One day |
- do- |
|
Schedule - IV |
200 Engine hour |
Two days |
Mobile van |
|
Schedule - V |
1000 Engine hour |
Seven days |
Workshop(IOH/POH) |
|
Schedule - VI |
2000 Engine hour |
Forty five days |
Workshop (IOH) |
|
Schedule - VII |
6000 Engine hour |
Ninety days |
Workshop (POH) |
The maintenance schedules as above should be strictly followed and the machine staff should be given adequate time to carry out the schedules. Items to be checked and attended under various schedules, shall be as per RDSO's publications for individual machines/manufacturer's recommendations. Such maintenance schedules/inspection check-lists for the following machines have been issued by RDSO:-
(i) Unomatic Tie Tamping machine (08-16)
(ii) Duomatic Tie Tamping machine (08-32)
(iii) Continuous Tamping Machine (CSM 09-32)
(iv) 09-3X CSM Tamping Express
(v) Points and Crossing Tamping Machine (UNIMAT)
(vi) Unimat Compact-M
(vii) Ballast Cleaning Machine (RM-80)
(viii) Shoulder Ballast Cleaning Machine (FRM-80)
(ix) Ballast regulating machine (BRM)
(x) PQRS
(xi) Turn out changing machine T-28
(xii) Track Relaying Train (P811S)
Workshops, to deal above schedules, shall be following five levels:-
i) Central Periodical Overhauling Workshop (CPOH)
ii) Intermediate Overhauling Workshop (IOH)/Zonal Base Depot
iii) Satellite depot
iv) Mobile Workshop
v) Camp Coach Workshop
6.3.1 Central Periodical Overhauling
Workshop (CPOH)
At present, there is one CPOH Workshop at Allahabad, catering to the POH of tamping machines. POH of other machines is carried out by Zonal Railways, as prescribed by the OEM. The functions of CPOH workshop are as under:-
i) P.O.H. of machines
ii) Overhauling of tamping units, gear assembly, axle assembly and lifting, - lining assembly for unit exchange either at shop floor or field.
iii) Post POHs Service to Zonal Railways and performance monitoring of overhauled items
iv) Development of expertise, standardisation/documentation/dissemination of knowledge with respect to overhauling of assemblies.
v) Study of inter-changeability of components and sub-assemblies.
vi) Study of failures, finding out remedial measures, trouble shooting and development of maintenance practices.
(vii) Procurement of stores and equipments required for POH and their inspection.
(viii) Inspection and testing of machines/assemblies received prior to and after POH.
(ix) Study of new imported machines and preparation of inventory list with complete series of machines (machine-wise) and checking for changes with reference to old series of machines.
(x) Development of indigenous substitutes and reliable competitive sources of supply.
(xi) Development of drawings and material specifications for manufacture of spares.
(xii) Providing shop floor training regarding maintenance of machines.
The crew incharge of the machine shall accompany the machine sent for POH to CPOH workshop and associate in overhauling of the machine throughout. The zonal railway should make out a detailed report about the health of machine being sent for CPOH, indicating the history of defects and failures of the machine and sent it to Dy.CE/CPOH at least one month in advance of arrival of the machine, for CPOH workshop to take preparatory action. The zonal railway should sent the complete machine without removing any of the part before POH.
After overhauling of the machine, the staff of the machine shall receive the machine only after all the tests and trials have been carried out. An officer of the owning railway should be present during the testing and trials.
The CPOH workshop shall stand warranty for satisfactory working of the machine, for a period of six months after commissioning of the machine. CPOH workshop shall advise the machine holding railway about the indigenous components used in the overhauled/repaired assemblies and the zonal railways shall submit feedback to CPOH workshop about their performance.
For overhauling of tamping units, the railways will plan their annual requirements and advise the CPOH workshop in advance. Also the railways will make their own arrangements for transportation of tamping units from the workshop.
Model activity flow chart for POH of tamping machine is shown in Annexure 6.1. Typical list of facilities for CPOH workshop is given in Annexure 6.2.
6.3.2 Intermediate Overhauling Workshop/Zonal Base Depot
Normally, there shall be one IOH Workshop with each zonal railway. The IOH shall be carried out as per Schedule VI mentioned in para 6.2 unless otherwise stipulated by the OEM. Items like engine top overhaul, renewal of pumps and motors and valves, tyre tuming, attention to measuring system, attention to tamping unit and brakes etc should be attended. In addition, attention shall be given to other items on condition basis as per repeated failures reflected in the log-book. Proper advance preparation shall be done after survey of the machine to be overhauled. Normally, two IOHs shall be done before each POH. If POH/IOH at lesser interval is considered necessary, approval of Chief Track Engineer (Machines) should be obtained. Normally, such instances will arise only if there are major structural damages or cracks or major overhaul of power packs or major modifications are necessary. Heavy overhauling of assembly can be clubbed with POH when considerable stripping/disassembly is required to reach some important components for check or rehabilitation.
Typical facilities required at IOH workshop are mentioned in Annexure 6.2 along with CPOH Workshop facilities.
In addition to IOH workshop, zonal railways will set up Satellite Depots to meet the spares and maintenance needs of a group of 10-12 machines working nearby in one or more divisions.
The track machines shall be brought to the Satellite Depots for repairs, which can not be performed in the field. Facilities at Satellite Depots shall include stores for essential and consumable spares with facilities for housing the track machines and carrying out the repairs/assembly replacements and offices for supervisors/Officer-in-charge. The supervisor/officer incharge of the machine (s) shall also be in-charge of the Satellite Depot.
6.3.4 Mobile Workshop-cum-Transport Van
Each Railway shall have adequate number of Mobile Workshops (Road Vehicles) of adequate capacity to repair track machines, which are deployed all over the zone. The mobile workshop shall attend each track machine periodically to cover Schedules II to V and breakdown repairs. It will carry spares and consumables to be replenished. For this, sufficient inventory of spares will he maintained in the van. The mobile workshop shall he provided with well trained staff who can handle repair of various systems.
Typical facilities to be provide in a Mobile Workshop. are given in Table 6.1:-
Table-6.1
|
S.N. |
Items |
Quantity |
|
1 |
Two tonne crane/hoist to handle tamping unit, engine etc. |
1 |
|
2 |
Portable tent |
1 |
|
3 |
Portable Electric drill machine, Flexible shaft grinder |
1 each |
|
4 |
Bench grinder |
1 |
|
5 |
DG set 10 KVA |
1 |
|
6 |
Welding Plant |
1 |
|
7 |
Gas cutting equipment |
1 |
|
8 |
Work table -with bench vice, tool kit |
1 each |
|
9 |
Lighting arrangement |
1 |
|
10 |
Air Compressor (600 CC) |
1 |
|
11 |
First Aid Box |
1 |
|
12 |
Nominated inspection gadgets as prescribed by OEMs i.e. PLASSER, CUMMINS, MWM, ZF, DEUTZ, REXROTH, SKF, PARKER, DENISON |
1 set |
|
13 |
Heavy duty jacks, pullers, pushes upto 50 ton capacity |
1 set |
|
14 |
Multimeter |
1 |
|
15 |
Tachometer (Contactless) |
1 |
|
16 |
Small pay bars |
2 sets |
|
17 |
Temperature meter digital (contact type) |
1 |
|
18 |
Vibration (Frequency) Meter |
1 |
|
19 |
Reamers |
8 |
|
20 |
Seals installation kits |
1 set |
|
21 |
Bearing puller/ pushers, presses |
1 set |
|
22 |
Accumulator pressure checking and filling device PC-250 complete |
1 set |
|
23 |
Seal measurement kit |
1 |
|
24 |
Wheel defect gauge |
1 |
|
25 |
Torque Wrenches |
1 set |
|
26 |
Magnetic base dial gauge |
1 |
|
27 |
IC Tester, Relay Tester, Diode Tester |
1 |
|
28 |
O-ring cone |
1 |
|
29 |
Gauge cum level |
1 |
|
30 |
Pendulum calibration pads |
1 set |
|
31 |
Versine Measuring Chord |
1 |
|
32 |
Go-NO-Go gauge for tamping tynes |
1 set |
|
33 |
Hydrometer |
1 |
Camp Coach shall be attached with each machine. It shall contain provisions of small Workshop. These shall be manufactured or re-furnished as per the drawing issued by RDSO.
i) Function of Camp Coach Workshop
It will cater for Schedules I, II, & occasionally III. The spares and equipment for minor repairs and daily usage shall be kept on camp coach.
ii) Typical list of equipments to be kept in Camp Coach Workshop are given in Table 6.2:-
Table -6.2
|
S.N. |
Items |
Quantity |
|
1. |
DG Set (5 KVA) |
1 |
|
2. |
Welding Plant |
1 |
|
3. |
Bench Grinder |
1 |
|
4. |
Bench vice and a work table |
1 |
|
5. |
Drill Machine |
1 |
|
6. |
Tool Kit |
1 |
|
7. |
Portable filter |
1 |
|
8. |
Portable Crimping Machine |
1 |
|
9. |
Heavy duty jacks, pullers, pushers upto 50 ton Capacity |
1 Set |
|
10. |
Hot Air Blowers |
1 |
|
11. |
Multimeter |
1 |
|
12. |
Accumulator pressure checking and filling device PC-250 complete |
1 set |
|
13. |
Torque Wrench |
1 Set |
|
14. |
Pendulum Calibration pads |
1 Set |
|
15. |
Versine Measuring Chord |
1 |
|
16. |
Go-NO-Go gauge for tamping tynes |
1 |
|
17. |
Tamping tool profile bore gauge |
2 |
|
18. |
Steel scale 1" to 6" |
1 Set |
|
19. |
Taper gauge upto 1" |
1 |
|
20. |
Feeler gauge |
1 |
|
21. |
Thread gauge |
1 |
|
22. |
Cell Tester(Battery Voltage) |
1 |
