Co-ordination meeting for Reviewing the Safety and Shop
SSETECHNICAL1
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Jul 11, 2024
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About This Presentation
Safety Meeting Presentation
Size: 1.88 MB
Language: en
Added: Jul 11, 2024
Slides: 48 pages
Slide Content
CO-ORDINATION MEETING
CUM SAFETY SEMINAR
ON
Mechanical Workshop
Gorakhpur
WORK DONE FOR ENHANCING SAFETY
Total Number of coach checked 27
Defect Found in 6 coaches (Fastener found loose and
missing)
Checking of LHB Roof ventilator
RAILWAY BOARD DRIVE
CBC lock pin modification
Fixture developed for modification
Being done in all coaches
180 Coaches modification done in 2023-24
Control Arm maintenance activity
DeWheeling
Sent for silent bush
removal
Internal Dia Measurement
Thread Checking
GO-NO GO for thread
checking
Application anti corrosion
Balasol
Sending for grit blasting
Sending for Repair
Pressing of Silent Bush
WORK DONE FOR ENHANCING SAFETY
Control Arm maintenance activity
Checking of Parallelism Blasol Application
Internal Dia measurement GO-NO GO for thread
checking
Application anti corrosion Balasol
Torquing of Bolts Marking on bolts
Fillingofwaterinwatercylinder,
Cleaningofsmoke&Heatdetector
orreplacement.
Final testing of FDSS System.
Checking of Suppression system
pressure in nitrogen cylinder.
Working range-150-200 kg/cm2
Checking of Smoke/Heat detector
physical condition
Smoke test for all point type smoke
detectors of Pantry Car/Power Car
Demonstration of manual activation of
suppression system
Heat detection test for all point type
Heat detectors of Pantry Car/Power Car
Checking of Linear Heat Detector cables
fitted in Generator room of Power
car/Pantry area of Pantry Car/Luggage
room of Power Car
Checking the Condition of pipelines,
wiring, fasteners, Nozzles
Demonstration of Faults
Pre-Check
Checkforallcomponentlike-
PowerSupply,FDSScontrolunit,
NitrogencylinderPressure,
Solenoidvalve,LHDcable,Heat
sensor,Smokesensor,Speaker,
flasher,hooteretc.
Checkingofcontinuityofwires,
Repair/ReplacementofMain
controlPanelifrequired.
TESTING OF FDSS
WORK DONE FOR ENHANCING SAFETY
•Fire and safety training
-750 Nos. staff and RPF personnel trained during FY 23-24.
-600 Nos. staff and RPF personnel trained during FY 24-25 (Till 30 May24).
WORK DONE FOR ENHANCING SAFETY
Mechanical Items 2024-25 2023-24 2022-23
Provision of aspiration type smoke detector in lavarea in AC
Coaches
55 104 0
Provision of FDSS in power/pantry car 19 24
Provision FSDS in AC coaches 8 203 73
Upgradation of manual to auto FDSS 7 0
Installation of anti theft fire extinguisher 100% fitment
WORK DONE FOR ENHANCING SAFETY
Mechanical Items 2024-252023-242022-23
FIBA Modification (Coach set) 426 235
Provision of additional dirt collector in BP line before FIBA device192 11
Revised wiring layout with modified junction box 170 170
Electrical Items 2024-25 2023-24 2022-23
Water proof bellows made of fire retardant material with metallic
frame at both ends (Meta/Para Armide) (Coaches)
39-LHB
09-Power
Car
-
Development and Provision of over voltage protection scheme for
HOG supply in 1850 Power Car
70 -
Interlocking of heater with blower motor 48 -
Standardization of Location of NTC sensor, OHP and ESTI 20
Aerosol based fire detection and suppression system cartridge for
13350 LHB AC coaches
17 -
WORK DONE FOR ENHANCING SAFETY
Other Modifications
Mechanical Items 2024-25 2023-24 2022-23
Installation of PFS 249 102
Epoxy flooring in LAV (Coaches) 473 -
Vinyl wrapping in Toilet and gangway area (coaches) 242 -
Modification of existing 3 phase MEMU rake to upgrade speed upto
110 kmph.
48 0
SAE 100 R3 type hose pipes in
place of SAE 100 RlAT (less flexible) to be used.
100% compliance
Dump Valve choke sizes 100% compliance
Self lubricating bushes for brake callipers/actuator 100% compliance in SS-III
Electrical Items 2024-252023-242022-23
Bypass provision of extending supply to OMS/RA coach 58 06
Provision of individual MPCB for water pump and shifting of its controller
to on board in set of panel for LHB Non AC/EOG coaches.
20 10
Provision of manual isolating switch with fuse to isolate the DA set starter
motor after start of DA set.
07 0
Modification sheet for shifting of RCBO position in set of panels for Non
AC LHB Coaches
171 -
separation of luggage light circuit from rest light circuit 4 -
Other Modifications
PH-42 WORK CLOSOURE REPORT
S.
No.
Sanc. Year Name of Works Alloc.Latest Sanc.
Cost
Total
expenditure
occurred
Finac.
Prog.
Phy. Prog. Remarks
12019-20Umbrella Work:
Extension of covered shed
in west of Furnishing -II
RRSK 17111 1684 12% 25%Work closed physically on 23/12/2022 and
financially on 01/07/2023. Work short closed
& deleted from IRPSM portal on 19/09/2023.
22020-21GKPS-Development of
facilities for repairing,
handling and testing of
Electro-pneumatic Braking
System of MEMU Coaches.
DF-36757 (Mech=
4753
Civil=
1739,
E=266)
5191 100% 100%Work completed physically on 31/01/2023 and
financially on 25/07/2023. Work Deleted from
IRPSM Portal on 04/09/2023.
32021-22GKPS-Construction of CC
Road from Paint Shop to
Out Going Inspection Shed.
DRF 8403 4196 100% 100%Work completed physically on 31/12/2023 and
financially on 26/02/2024. Work Deleted from
IRPSM Portal on 28/02/2024.
42021-22GKPS-Extension of CMT
Lab.
DF-3 1722 897 100% 100%Work completed physically on 31/07/2023 and
financially on 22/09/2023. Work Deleted from
IRPSM Portal on 04/10/2023.
52021-22GKPS-Construction of car
and two wheeler vehicle
shed.
DF-3 9769 637 4% 35%Work closed physically on 31/10/2023 and
financially on 29/01/2024. Work short closed
& Deleted from IRPSM Portal on 02/02/2024.
Summary
Target Actual Performance
Work Closed in 2023-24 1 5
Work Planned for closure in 2024-25 10
Works closed under PH-42 during FY:2023-24
PH-42 WORK CLOSOURE REPORT
S.
No.
Sanc. Year Name of Works Sanc. Cost(in
Cr. Of Rs)
Phy. Prog.TDC as per IRPSM Remarks
1 2017-18GKPS-Facilities for POH
maintenance of LHB coaches
for 20 Coaches/month
50.64 100% 30.06.2024
2 2018-19GKPS-Improvement in
infrastructure of Work Centre
for Rolling Stock Maintenance
Workshop
6.42 90% 30.06.2024Work in Progress:-2x1000 KVA CSS received on
29/03/2024 and is under commissioning.
3 2019-20Automation in working,
inspection, record keeping and
record transmission in
workshop
6.61 100% 15.06.2024Work Completed and deleted from IRPSM Portal on
28/05/2024.
4 2019-20Extension of covered shed with
ventilator at the east end of
Bogie shop and construction of
ladies change room beside
office of Bogie shop.
2.08 72% 31.01.2025work completed:-All trusses erected in east side of
bogie shop & Shed in 04 nos. bays in west of fur-ll
shop constructed.
Work in Progress:-Gantry girder fixing in east side
of bogie shop & Foundation PCC work in Fur-llshop
under progress.
5 2021-22GKPS-Extension of AC shed
with Crane Gantry for EOT
Crane
2.49 45% 31.03.2025Work completed-Shed extension in 21 m length
completed. Electrical office building completed.
Work in progress-Low height shed construction &
Renovation of Coach wiring building under progress.
Works identified for closure under PH-42 during FY:2024-25
PH-42 WORK CLOSURE REPORT
S. No.Sanc. Year Name of Works Sanc. Cost(in Cr.
Of Rs)
Phy. Prog.TDC as per
IRPSM
Remarks
6.2021-22Provision of new drains for
improvement of drainage system
2.01 78% 31.10.2024Work completed-Drain for East & west Traverser, yard
office to Personal office, Personal office to Main Drain,
yard to main drain completed.
Work in progress.-Drain connectivity between GER &
TL shop under progress.
7.2021-22Construction of heavy-duty CC
floor in east and west traverser
bay
1.10 80% 30.06.2024Work completed-75% work of CC flooring in the east
traverser completed.
Work in progress-Casting work of remaining traverser
floor area under progress.
8.2021-22Extension of Shed of Screw
Coupling Section & Divisional
Failure Response and Analysis
(DFRA) Cell
2.20 30% 31.01.2025Workcompleted-TrusseserectedinScrewcoupling
section&Plasterworkcompletedfor(DFRA)Cell
office.
Workinprogress-FixingofgantrygirderinScrew
couplingsection&Flooringworkin(DFRA)Cell
officeisinprogress.
9.2022-23Replacement of damaged AC
sheet and Wooden trusses with
Galvanized Iron Profile sheet and
Steel Trusses in WTC
1.69 58% 31.10.2024Work completed-Truss erection and shed work
completed for WTC hall (1
st
to 6
th)
.
Work in progress-Renovation of old WTC building
under progress.
Works identified for closure under PH-42 during FY:2024-25
PH-42 WORK CLOSOURE REPORT
S. No.Sanc. Year Name of Works Sanc. Cost(in
Cr. Of Rs)
Phy. Prog.TDC as per
IRPSM
Remarks
10.2022-23Renovation of Ward No. 77&
88.
0.84 45%31.10.2024Work completed-Renovation of Ward-77 (Hall-01)
Completed.
Work in progress-Hall-2 and ward-88 renovation
under progress.
11.2022-23Provision of CC Road in lieu of
Old bituminous road form main
gate to IC gate and other
location.
2.43 40%31.03.2025Work completed-CC road from oil godownto cutting
cloth factory, from north side of union office to scrap
bin completed. TOP CC road casting work in mid road
between platform -2 & 3 completed.
Work in progress-Road infrontof Rejection ward
under process.
12.2022-23Construction of Sheds &
Repairing of Bins and Roads.
2.21 50%28.02.2025Work completed-Sheeting and PCC of 128m length
completed. 2nd shed sheeting work completed.
Flooring working in1st and 2nd shed completed.
Work in progress-Making of protection grill in 1st
shed & Foundation for 03 more sheds under progress.
13.2022-23Provision of New Toilet Blocks
(Two Nos.)
0.41 35%31.12.2024Work completed-1st toilet 90% work completed.
Work in progress-2nd toilet dismantling work & 1st
toilet final finishing work under progress.
Works identified for closure under PH-42 during FY:2024-25
30 ICF to NMGHS Coach conversion was done in month
Jan’24 by MWS, GKP (Highest ever by any IR Workshop)
Shell shop Outturn-202 coaches was done in Month
July’23 (Highest ever in Workshop)
ACHIEVEMENT, GOOD WORK, INNOVATION DONE
ProvisionofLinenroominACCNEEconomy
CoachesasperRCF CAINo.-
CAI/RCF/MECH/LHB/038startedinMay’24.
05NoEconomyCoaches(ACCNE)forSS-IIhave
arrivedatMechanicalWorkshopGorakhpurby
May2024,provisionofLinenroomhasbeenmade
inallofthem.
Linen Room in Economy Class ACCNE Coaches
ACHIEVEMENT, GOOD WORK, INNOVATION DONE
SS-IPowercartrolleybeingdispatchedinadvance
AverageCycletimereducedto….DaysinMay’24
Power Car SS-I Trolley
ACHIEVEMENT, GOOD WORK, INNOVATION DONE
NRVhadbeenprovisionedbetween
IsolatingcockandAFRLinpneumatic
lineofElectro-PneumaticPressurized
FlushingSystemasperMCFCAIand
letterNoRBL-MD46111-XII(Pt-1),Vol-I
Dt02-01-2024.
71NoofCoachesmodifiedtillMay’24
Benefits:
Preventwater/moistureingressfrom
EPFStoairbrakepipeline.
Provision of NRV in Pneumatic line of Electro-Pressurized Flushing System (EPFS)
ACHIEVEMENT, GOOD WORK, INNOVATION DONE
This machine is used to press-out INNER RACE &
THROWER mounted on axle journal of 3-PHASE Electric
Loco wheel (WAP7/WAG9).
Earlier, the INNER RACE was taken out by heating it with
the help of INDUCTION COIL due to which the INNER
RACE could not be reused.
Benefits:
Now60-70%Innerraceisre-usedincomparisonto
100%rejectionearlier.
Electricitysavingupto50%
MOTERISED HYDRAULIC PRESS MACHINE
ACHIEVEMENT, GOOD WORK, INNOVATION DONE
Portable hand held marking
machine is being used for Axle
end punch marking.
Earlier, this was done using
hand punch.
This helps in standardization
and faster marking of axle.
Portable Hand held Axle end Marking Machine
ACHIEVEMENT, GOOD WORK, INNOVATION DONE
Thermo-plastic paint Road marking
machine has been procured for marking of
road.
This helps in pathway marking with special
paint.
Improved path visibility and marking
durability.
Thermo-plastic Road Marking Machine
ACHIEVEMENT, GOOD WORK, INNOVATION DONE
Earlier lettering work on End Panel was done manually.
Now, 100% Screen Printing of side wall and end wall is being done.
Screen printing frame were developed as per Rolling Stock requirements.
This led to standardization and quality improvement in Lettering work.
ACHIEVEMENT, GOOD WORK, INNOVATION DONE
Shop Schedule activity wise must change kit of fasteners had been packed in bags and started to
be provided to Gang in Bogie shop.
This will prevent use of old fasteners during must change bogie maintenance activity.
ACHIEVEMENT, GOOD WORK, INNOVATION DONE
Tamper proof torque marking paste has been started on pilot basis for identification of vibratory
loosening or tempering on nuts, bolts, Fasteners, and assemblies.
This offers advantage of Highly visible fluorescent Colors & Excellent adhesion as well as safe on
metal features in comparison to paint marking being done as existing practice.
ACHIEVEMENT, GOOD WORK, INNOVATION DONE
WSP Data Analysis:
Data is being downloaded in incoming condition of all 3 make (KBIL, FTIL, Escorts) LHB Coaches.
Data is analyzed by downloaded data through aggregator file.
Error is cross-checked with physical condition of WSP System and recorded.
In case, no physical damage is found, advice to shop is given to check Brake Cylinder, Brake
Calipers and other associate parts of WSP during overhauling
ACHIEVEMENT, GOOD WORK, INNOVATION DONE
Automatic Air Spring Leakage Testing machine had been commissioned in Air
Brake shop.
4 Air Springs can be tested simultaneously at a time.
Saves time, manpower and improved reliability.
ACHIEVEMENT, GOOD WORK, INNOVATION DONE
Automatic Air Spring Leakage Testing Machine
Plastic pellets procured for Helical spring stacking
Improved space management
Prevention of rusting from floor moisture and dust
ACHIEVEMENT, GOOD WORK, INNOVATION DONE
Helical Spring stacking in Spring Shop
Material Handling Bins:
Material Handling bin had been
developed in-house for dampers using
old battery box.
This prevents damage during
transportation and help to ease in
working.
Similar bins have been developed for
other items like Brake Caliper, Control
Arm, etc.
ACHIEVEMENT, GOOD WORK, INNOVATION DONE
Waste Management (स्वच्छकारखानाअभियान):
128 Scrap bins have been developed and placed extensively as per
workshop Scrap Bin placement plan in various shops viz. Furnishing,
Paint, Shell etc.
Scrap trolley movement plan and monitoring being done.
Counselling and swachhta pledge administered at shop floor to the
employees.
ACHIEVEMENT, GOOD WORK, INNOVATION DONE
Time study for revision of Allowed Time in Shell, Paint and Furnishing Shop done in accordance with
work process up-gradation.
Reduction of upto56% in AT was done as shown below.
ACHIEVEMENT, GOOD WORK, INNOVATION DONE
SHOP DESCRIPTION OF ACTIVITIES % Reduction in Allowed Time afterrevision
SHELL Gas cutting external panel (rough) 10%
Fitting on external panel 20%
Welding of external panel 20%
PAINT Repair of one seater 10%
Repair of AC back rest 10%
FURNISHING Partition make new 20%
Floor board stripping & fitting 10%
Banjo window renew with APD 5%
Stripping & fitting of W/frame 5%
WHEEL ICF wheel set press in 17%
LHB Wheel set Press out 25%
LHB Wheel set Press in 56%
Roller bearing mounting & dismounting 13%
Installation-of 45 Numbers New street light Pole has been
done to enhance illumination of road.
3 number IGBT based Battery Charging systemhas been
installed in TL shop.
LT overhead of Auxiliary Feeder has been replaced by
underground cabling.
ACHIEVEMENT, GOOD WORK, INNOVATION DONE
Battery Charging system
ACHIEVEMENT, GOOD WORK, INNOVATION DONE
IRIS Certification:
IRISCertification®isaglobalsystemenablingthe
railsectortobenefitfromastrongand
recognizedevaluationmethod.
GorakhpurWorkshopwillbefirstIRIScertified
WorkshopinIndianRailways.
Benefits:
Prevent problems from reoccurring.
Improve employee performance.
Improve control over activity.
ACHIEVEMENT, GOOD WORK, INNOVATION DONE
Sl.No.Certificates Issue dateValid upto
1.
ISO 50001 26.07.202125.07.2024
2.
Green –Co Rating (Gold) 15.07.202214.07.2025
3.
IRIS (International Railway Industry Standard)13.01.202416.12.2026
4.
ISO 3834 21.01.202420.01.2027
5.
NABL 27.02.202426.02.2026
6.
IMS Certification 09.03.202408.03.2027
7.
5S Certification 09.03.202408.03.2027
CERTIFICATES:
CONSIGNEE
No. of
Claims
Total Orig.
Claim Value
Total Value of
Claim
Withdrawn
Total With-
held/Recovered
Amount
Total Refund
Amount
Total Value of
Replaced Qty.
Total Value of
Rectified Qty.
Total Bal. Claim
Value
GRAND TOTAL
565 1289.74 36.43 246.19 87.88 55.59 873.07 187.17
091112
SSE/FUR-I/STORE
6 1.93 0 0.77 0 0 0 1.16
091145
SSE/BREAK SHOP
179 624.15 16.31 161.75 80.70 0.18 391.13 137.44
091182
SSE/WATER TANK
7 10.02 0.40 3.32 0 0 2.45 3.84
091200
SSE/BOGIE SHOP
315 91.50 0 72.36 6.41 25.23 0.66
8.62
091315
SSE/MILL WRIGHT SHOP
12 467.01 9.15 1.59 0 1.59 456.27 0
091340
SSE/PAINT SHOP
19 3.13 0 2.0 0.77 0.82 0.22 0.87
091420
SSE/WHEEL SHOP
15 40.43 10.57 4.36 0 27.77 5.75 0
091728
SSE/COACH WIRING
2 1.13 0 0 0 0 1.13 0
091625
SSE/PM
1 0.04 0 0.04 0 0 0 0
091741
SSE/AC
8 49.93 0 0 0 0 15.46 34.77
091753
SSE/GER2
1 0.47 0 0 0 0 0 0.47
(Figures in lakh of Rs.)
WARRANTY CLAIM STATUS
TARGET FOR 2024-25
COACH TYPE ICF ACICF NACNMGHNMGHSMEMU
LHB ACLHB NAC
Total
SS-IISS-IIISS-IISS-III
Target (2024-25)
per month
11 67.9 20.814.28.3 38 33 193.2
Yearly Target
(2024-25) 132 815 250 170100 456 396 2319
RO Wheels to NER
MONTH
& YEAR
LHB
GKP LJN CPR BSBS TOTAL
R D R D R D R D R D
APRIL-23 34 36 0 0 4 4 0 8 38 48
MAY-23 50 38 4 4 4 4 8 62 50
JUNE-23 73 75 1612 4 12 93 99
JULY-23 37 27 4 2 0 39 31
AUG-23 29 33 7 7 4 4 40 44
SEPT-23 21 27 3 4 8 4 32 35
OCT-23 26 57 5 121214 52 74
NOV-23 54 44 4 4 12 4 4 66 60
DEC-23 37 37 6 4 12 4 4 59 45
JAN-24 36 30 1410 50 40
FEB-24 41 36 2018 4 4 65 58
MAR-24 22 25 8 8 4 8 1212 46 53
TOTAL
GKPS Bogie Target 2023-24
Item NER FR NMG +
NMGHS
Total
SS2 47 24 71
POH 40 38 35 113
SS1 57 25 82
IOH
42*
Total 87 308
•Avg Bogie Outturn of last 4 months is 297 coach set (Max 306 in Dec 2023)with current rate of
wheel rejection.
•In current rate of rejection only 31 (297-266)coach sets IOH (avg) can be given.
Note: In month of April total bogie requirement of NER is 277 coach (including 94 IOH) set
bogie.
Wheel Condemnation Status for Apr’24
ASSISTANCE REQUIRED
Due to Wheel pressing constraints, LOCO Wheel pressing load of GKPS may be
shifted to IZNS
LHB Axle allotment is required.