C&W_open_line

8/4/2019 C&W_open_line

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Work Profile in C & WWork Profile in C & W

Depots of IndianDepots of IndianRailwaysRailways

Presented by

M.T.Sujith Kumar SE / C&W / BBQ


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ENGINEERS & STAFF OFENGINEERS & STAFF OFOPEN LINEOPEN LINE

SENIOR SECTION ENGIN EER

JUNIOR ENGINEER

ARTIZANS (THREE GRADES)


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Work AreasWork AreasAs In-charge of Depot, IOH/ROH Sheds, Sick

line, M & P, Stores, Break Down, MIS andRake Maintenance activities in C & W Depots.As C&W, M&P and Safety Inspectors inDivisional and Zonal Headquarters.As Instructors & Lecturers at STCs and BTCs.As C&W Controllers in Divisional and Zonalcontrol offices.


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DUTIES ,RESPONSIBILITIES& REQUIREMENTS

OFOPEN LINEENGINEERS


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ADMINISTRATIVE DUTIESADMINISTRATIVE DUTIES

Depot InDepot In --chargechargeResponsible for all activities in the Depot.

-Technical, Administrative, Ministerial, etcand for Effective execution of administrativepolicies and plans.

Maintain Out-turn targets and train schedules.Efficient Stores & Material Management.Effective Human Resource Management.Provide on the job training for trainees,apprentices & conducting trade test, suitabilitytest etc.


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ADMINISTRATIVE DUTIESADMINISTRATIVE DUTIES Cont..Cont..

Plan for capacity augmentation in Infrastructure,machinery, plant, material and manpower.Preparation of Tender & Liaison with out sideagencies for Out sourcing, technical suitability,vendor rating, implementation of contractualobligation etc.Preparation of annual M&P and works programme

& maintenance of M&P and related equipments.Maintenance of Industrial peace, Staff discipline,DAR proceedings etc.


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ADMINISTRATIVE DUTIESADMINISTRATIVE DUTIES Cont..Cont..Ensure safety of Men, Material and Traveling

Public through intensive Supervision and QualityControl.Maintenance of Accident relief trains including

Re-railing equipment, First aid equipment, spares,cranes, etc.Effective Disaster Management. Restoring

normalcy during natural calamities and accidents.Maintain the integrity and punctuality of Trainservices during natural calamities like flood, stormetc.


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TECHNICAL DUTIESTECHNICAL DUTIES

Maintenance, Repair and Certification of the entireRolling Stock Inventory of Indian railways comprising 2.3lakh Wagons 48500 Coaches for Safe, Reliable and Punctual Train

operation.Planning of maintenance activities including placementof rakes in Pit Lines, balancing of rake occupation in PitLines.Detachment of Coaches and Wagons for Scheduledmaintenance activities like POH and IOH / ROH, etc.


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Preventive Maintenance activities of Coaches andWagons in Pit Lines and Yards. (Examination andrectification of each and every component, for anyfailures, abnormalities and unsafe condition, which mayendanger the safety of the train.Analysis and reporting of component failures.Certification of the entire train for its overall safety tillthe train returns to the originating station.Maintenance of all registers with respect to train service.Issuance of Brake Power Certificate.

TECHNICAL DUTIESTECHNICAL DUTIES Cont..


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TECHNICAL DUTIESTECHNICAL DUTIES Cont..

Maintenance and upkeep of Brake Down specials.

Planning and execution of re-railment andrestoration at accident sites.Maintenance activities in Sick lines and ROH/IOHSheds.Upkeep of Machineries and plants.Monitoring of trial components.Prevention and analysis of enroute failures liketrain parting, brake binding, hot axle, etc .


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Need to posses the complete technical knowledge / working knowledge of the rolling stock as a wholeand all its individual components.

Need to posses the technical knowledge of all the Rollingstock manufactured in the past few decades till theircomplete life span

Whenever new technologies are introduced, adapt to thenew technology by self-learning.

Impart training to field staff to update the latest technicaldevelopments in rolling stock.

SPECIAL REQUIREMENTS of OPEN LINE ENGINEERS


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ACCOUNTABILITYACCOUNTABILITY

Custodian of all assets including Machineries andPlant, Stores and other related equipments worth

several crores.Planning and Running of special trainsSubject to Audit by the Divisional Audit Personnel.

For any failure of the system in train service.For out turn target of wagons/coaches in sick lines andIntermediate / Routine Overhauling.

For detention of trains on C&W accountFor any failure in components of the certified train.For any failure in the brake power.


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MULTIFACETED SKILLS & ROLESMULTIFACETED SKILLS & ROLESAdministrative abilities to manage and run Depots.Possess up to date Technical knowledge of various types of Rolling stock and its components.Managerial Skills to manage the work force to meet thequality and safety standards.Assess the knowledge level of work force under him forproper distribution of work.

Ministerial skills to ensure proper recording of the data.Technical scrutiny of tender papers for procurement of Rolling Stock components and services.


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MULTIFACETED SKILLSMULTIFACETED SKILLS ( Cont..)( Cont..)Tutor and mentor to educate the work force continuouslyto keep up with modernization.

Complete Knowledge of DAR proceedings to tackle erringstaff.Planning for improvements.

Crisis management for restoration in case of accident orbreakdown.Failure analysis and Investigation to find out and rectifythe reasons.Maintenance of Accident relief trains including Re-railingequipment, First aid equipment, spares, cranes, etc.


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Duties performed byDuties performed byOpen Line C&WOpen Line C&W

Engineers duringEngineers during

Train maintenanceTrain maintenance


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BASIN BRIDGECOACHING DEPOTCh ennai Division / S.Rly

is taken for Illustration

BBQ The only C&W maintenancedepot ISO certified for its entireoperations in Indian Railways.


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Coach Position of BBQCoach Position of BBQBARE REQUIREMENT - 755INEFFECTIVE - 75.48(12% FOR AC AND 10 % FOR NON AC) ----------

TOTAL (A) - 830.48TRAFFIC SPARE (B) - 94.38(12.5%) OF A ----------TOTAL REQUIREMENT (A+B) - 925ACTUAL AVAILABLE - 807SHORTAGE * - - 118

* The shortage results in coaches being cannibalized from otherincoming rakes to meet the demand depriving them of themandatory maintenance time


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Coach MaintenanceCoach Maintenance

Sick Lines / IOH ShedsBreak Down Attention & C-Schedule / IOH Attention

Yard / PlatformMaintenance of Accident

Relief Trains

PlatformsOther End Attention

PlatformsPlatform Turn-aroundAttention

Pit Lines in YardSecondary MaintenancePit Lines in Yard

Primary Maintenance

PlaceType


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Primary MaintenancePrimary Maintenance-- Carried out for the Train as a wholeCarried out for the Train as a whole

Need - Mandatory for every train.Place - Pit Lines in Coaching yards.Works - Safety, Amenity, Electrical, A/C, Internal

& External cleaning and Brake powertesting with certification.

Time - Minimum 6 Hrs in Pit lines.Day/Night - Both Day & Night.Lighting - Ambient light during day time and

primitive minor lamps during night.

Validity - Up to 3500 Kms Max.


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PITLINE MAINTENANCE

Inspection, testing and attention of all the vital safety components

both visually and using inspectiontools and gauges to ensure safety

of the whole train.


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Thorough examination and attention to the

brake system to ensure 100 % brake power.Inspection and testing of Passenger

emergency alarm system.Ensuring the availability of correct destination

and coach indication boards.

Testing and attention of all Electrical fittings& equipments(, batteries, alternators, lights &fans)

PITLINE MAINTENANCECont


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Ensuring availability and working of allpassenger amenity and safety fittings.Exterior and interior Cleaning of coachesusing chemicals and detergents.Watering of all the coaches.

Execution of all Preventive Maintenanceschedules.(A & B Schedules as per IRCApart IV)

PITLINE MAINTENANCECont..


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Vital Safety ComponentsVital Safety ComponentsRunning Gear ComponentsSuspension Gear ComponentsDraw & Buffing gear componentsBrake gear componentsUnder frame & Bogie ComponentsAir-conditioning equipmentsElectrical Equipments


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Components that must be ExaminedComponents that must be Examined

During Pit ExaminationDuring Pit Examination

1012 mts46 mts (Aprox)Pipe Lines

6666303Total

2420110Under Gear

143065Brake Gear

61628Draw & BuffingGear

176080Suspension Gear

44020Running Gear

Per rake of 22Coaches

Major Components /Coach


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2640 Sq Mtrs120 Sq MtrsExterior cleaned

22010Doors & Fasteners(Main / Toilet) &

Vestibules

158472

Window shutters &

Fastenings

35200 ltrs1600 ltrsWater to be filled

30814Flush/Push cocks,

Taps & Valves

Rake of 22 CoachesPer Coach

Other Components & ActivitiesOther Components & Activities


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This apart the availabilityand correctness of more than

145 Cotters & Split pins&

150 Bolts and nuts

in every coach need to bephysically ensured


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PLATFORM MAINTENANCERECEPTION

ROLLING IN EXAMINATION(Visual inspection of dangling parts, hearing for any unusualsound)

AXLE BOX FEELING

(Sensing the temperature of axle boxes by thermo hunters / hand by kneeling down in the gap between platforms andcoach)

RELEASING OF BRAKES(Manually pulling of DV release valve by kneeling down in the

gap between platforms and coach)


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DESPATCH

PLATFORM MAINTENANCE(Examination,cleaning ,watering and certification of platformturnaround trains and pass through trains ensuring safety)

CONTINUITY CHECK(Connecting all the air hoses of coaches and ensuring the continuity of air pressure through the formation)

ROLLING OUT EXAMINATION(Visual inspection of dangling parts, hearing for any unusual sound)

PLATFORM MAINTENANCE Cont..


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SICK LINE MAINTENANCE

Execution of preventive Maintenance SchedulesIOH & C- Schedule as per IRCA Part IV.

Carrying out break-down maintenance.(To maintain the prescribed ineffective percentageof 2.5% of total coach holding)

Any other special works nominated by authorities.


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To be alert on duty round the clock and respondingto the accident / derailment with in 20 min.

Arranging protection to passengers and theirbelongings.

Render first aid and arrange for medical assistance.Restoration of track and traffic (re - railing) within

the shortest possible time.

Investigation of causes and recommendation forpreventive action.Reclamation of assets.

ACCIDENT RELIEF TRAINS


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OTHER ACTIVITIES

Assessment , Procurement and Maintenance of Machinery and Plants & Tools and Plants.

Maintenance of saloons and inspection vehicles .Planning ,Procurement ,stocking and issue of items

required for day to day maintenance activities.Planning and processing of Outsourcing activities/

services.Maintenance of Management Information

Systems(MIS).Processing and maintaining ISO certification ,etc.


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Defects affecting Train safetyDefects affecting Train safety

222245360445473Under Gear

138181129179218Draw &

Buffing Gear

464492527634632Brake Gear278325445378461Suspension5105466531142861Running Gear

20072006200520042003Nature of Defects


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Interior DefectsInterior Defects

9511180113713121355Total

6087117166188Body Panel &Carpentry

167257228214203Berth & WindowShutters

275301332507505Main Door, Lav.

Door, PassageDoor & Vestibules

449535460425459Plumbing & Watertank repairs

20072006200520042003


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DASH POT SPRING BROKEN


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AXLE BOX COVER

PUNCTURED


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BOGIE FRAME CRACK


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BRAKE HANGER PIN MISSING


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BSS HANGER MISSING


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BUFFER PLUNGER BROKEN


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SIDE BEARER PILLAR CRACKED


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PITTED WHEEL


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SHELLED TREAD


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WORK ENVIRONMENTOpen- to - sky environment facing hot sun , heavy rain,

storms, cold weather etc.,

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

Haphazardly and unscientifically constructed Pit lines

without sufficient working space and facilities

Exposure / Contact with chemicals and other hazardouscompounds used for cleaning due to parallel executionof various maintenance activities (Electrical, Undergear Maintenance, Interior & Exterior cleaning and Air-conditioning maintenance)


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Sewage water stagnation due to improper / defectivedrainage facilities.

Insufficient lighting with only the primitive Miner Lampsto carry out the maintenance during Night.

Flooded Pit lines during monsoon.

Mosquito , Snake , Rat , Cattle and Stray dog Menace.Continuous exposure to 110V DC Power system which is

detrimental to health.

Exposure to Sulphuric acid in batteries.

WORK ENVIRONMENT Cont..


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WORK ENVIRONMENT Cont..

The staff engaged in inspection of rake/train has to walk a minimum of 1.5Kms around the rake and has to inspectaround 6000 components of safetycategory with in short span of time by

exerting himself by kneeling andstanding several times.


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C iC t i t


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ConstraintsConstraintsInsufficient Pit Maintenance Time

(Due to late running, Interconnection of trains, Bunching of Trains in both Departure and Arrival, Shunting movements, Crossmovements,etc.)

Haphazardly and Unscientifically constructed

Pit lines without sufficient working space andfacilities(Out of the 19 pit lines at BBQ only 2 conform to CAMTECH

norms)

Absence of proper Pit lighting & Yard lightingfor Night examination.

(Night Examination carried out with only primitive Miner lamps)


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ConstraintsConstraints Cont..Cont..

Lack of allocated spare coaches(Resort to cannibalization of coaches from otherrakes to replace sick coaches)

Indiscriminate running of Special Trainswithout sufficient Coaches.(Resulting in reduced maintenance time for

coaches)Shortage of Staff


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SPECIAL TRAINS

These are trains operated

throughout the year in addition tothe regular trains for various

reasons


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Special Trains are operated for variousreasons.

To Clear Wait Listed PassengersFor Summer/ Winter VacationsDuring Festival / Pooja SeasonDuring Sabarimala pilgrimage Season

For Organized Tour Package Special Trains / Coaches.VIP MovementsInspections

Handing over of Other Division/Zonal CoachesTrains of Sister Depots for want of Pit lines / FacilitiesDedicated VP Specials ( Parcel Vans)

SPECIAL TRAINS Cont


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SPECIAL TRAINS Cont..

The coaches for the Special trains are brought from theTraffic spare coaches pooled in Railway Zonal Level

which are over and above the holding of the Depot as perthe requirement of that Region/Depot.

Demand of Special Trains/Coaches will vary fromRegion to Region as per the season.

No additional remuneration or Incentive for Running

Specials and Extra Coaches is provided to motivate for theextra work load of the special trains which is over andabove stipulated work load and norms.

Special Trains Maintained at BBQ


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52783064351254TOTAL

00393MAR

27315554FEB

9555457834JAN

8545054432DEC

816451448NOV

352434553026016OCT

152252521423914SEP

152252321618812AUG

24012213121087JUL

540274542648027JUN880405403289850MAY

404212341381847APR

CoachesServicesCoachesServicesCoachesServicesMonth

2008 20092007 20082006 2007

p


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IN SPITE OF ALL THESE PROBLEMS

THE TRAINS ARE EXAMINED ANDCERTIFIED IN TIME ONLY

BECAUSE OF THE COMMITMENT &SINCERITY OF THE TECHNICALSTAFF


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Impact of TechnicalImpact of TechnicalAdvancement &Advancement &ModernizationModernization


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Unlike other areas, the benefits of Technical advancements viz- Improvedcomponent reliability and modernmaterials has not reduced the workloadof technical staff.- The number of components to be examined

and certified during each maintenance hasincreased over the years.

- The responsibility of any failure still rests withthe Engineer last certified the train .

ImpactImpact Cont..Cont..

ImpactImpact CC t


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The advent of modern materials and technologyresulted in manifestation of new type of defects

and problems.- Introduction of Composite Brake Blocks resulted in7 new type of wheel failures.

The benefits of technical advancements areoffset by increased Kms and Load.- Validity of certification increased to3500 Kms for

Coaching and 7500 Kms for Wagons.

- Train composition increased to 60 wagons and 25Coaches.- Gross load of wagons increased up to 90 tons


ImpactImpact CC t


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The modern components with advanced

pneumatics and electronic controls demandsmore discretion and diversified knowledgeto maintain and repair.Eg.- CD Toilet System

Wheel Slide protectorsPneumatic suspension

Disc BrakesCoaching CBC , etc

ImpactImpact C tC t


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Types of Wagons and Coaches

increased over the years.No major change in Infrastructure andother facilities.New technology, materials and systemposes newer problems which need to be

addressed during maintenance withoutany prior training or guidance.

Technical v/s Commercial & Traffic StaffTechnical v/s Commercial & Traffic Staff


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Technical v/s Commercial & Traffic StaffTechnical v/s Commercial & Traffic Staff

directly involved in running of trainsdirectly involved in running of trains

Signal &Telecommunication

ControllersElectrical /AC

GuardsBridges

DriversAccount / AuditPermanent way

Yard Staff TTEsDiesel / Electric Loco

Station mastersBooking clerksC&W

TrafficCommercialTechnical

RECRUITMENT, QUALIFICATION ANDRECRUITMENT, QUALIFICATION AND


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TRAININGTRAININGJUNIOR ENGINEER (GP 4200)

50% - Direct recruitment through RRB3 Years Diploma in Engineering &1 Years In- plant training.

(Total 4 Years Qualification equal to Engineering

degree)

VI CPC observation that JE and Clerk are equal sinceboth have 3 years Qualification is wrong since JE hastotal 4 years Qualification.

Hence both pay cannot be equal and needs correctionHence both pay cannot be equal and needs correction .


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JUNIOR ENGINEERJUNIOR ENGINEER Cont..Cont..

The Duties and Responsibility of a JE is enormouswhen compared to a clerk with whom he isequated.JEs in open line bears highest responsibility in

safe running of trains.Have a direct element in running of trains alongwith drivers.

Drivers function start only after the issuance of BPC by Open line engineer

SECTION ENGINEER / Sr.SECTIONSECTION ENGINEER / Sr.SECTION


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ENGINEERENGINEER (GP 4600)(GP 4600)Both scales merged as SSEComposition of cadre 20% Direct recruits with 4 / 4 years Degree in Engineering

and One year In-plant training 80% promoted from Junior Engineers ( 4 Years total

qualification and 20 to 25 years of Experience)VI CPC observation that this category is equal to anyother Bachelor degree holder in arts, science orcommerce is totally wrong.SSE with such huge responsibility and accountability andOffice Superintendent cannot be kept in same scale inany angle of observation


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AVENUES OF PROMOTIONAVENUES OF PROMOTIONOnly one promotion for JE-II/JE- I from 4200

Grade Pay to SE/SSE with 4600 Grade Pay.

No promotion for SE/SSE with 4600 Grade

pay and must retire in same grade.

Only about 2% of Technical Supervisors inIndian Railways get promoted as Group Bofficers.

Even after this analysis submittedEven after this analysis submitted


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Even after this analysis submittedyin this study, if one decides thatin this study, if one decides that

JE = Clerk JE = Clerk SSE = OSSSE = OS

Then GOD only can save railwaysThen GOD only can save railwaysand only GOD need to beand only GOD need to be

appointed as Pay commissionappointed as Pay commissionchairmanchairman

Observation by IRTSA

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