Must Change Item During ROH & POH
Must Change Item During ROH & POH
Must Change Item During ROH & POH
Sub: Report on Must-Change Items in Freight Stock during POH & ROH
As per Item 2.9 of this office letter of even number dt. 11.10.12, a Committee
and
consitgfCRSE/(onver), SCRWM/JH, KGPW
Director/Wagon/RDSO (Secretary) was formed to study and recommend the must-
change items during POH & ROH.
The Committee has submitted its report which has been accepted by Board
(MM). The same is hereby forwarded for necessary appropriate action.
(Archana Mittal)
Dir. Mech. Engg. (Frt.)
End: As above
1. Terms of reference:
As per Railway Board's letter No. 2003/M(N)/951/22 dated 11-10-2012,
committee consisting of CRSE/CR (Convener), CRSE/SCR, CWM/JHSW,
CWM/KGPW and Director RDSO/Wagon (Secretary) is formed to study and
recommend the must-change items during POH & ROH.
2. Committee Members:
1) Shri. P.A. Lamghare, CRSE (Fr), Central Railway.... : Convener
2) Shri. M. Amarendra, CRSE, South Central Railway : Member
3) Shri. S.K. Gupta, CWM, Kharagpur Workshop Member
4) Shri. Shivendra Mohan, CWM, Jhansi Workshop : Member
5) Shri. Roopesh Srivastva, Director (W), RDSO • Secretary
3. Background:
There has been a spate of hot axle cases and train parting cases on Indian
Railways. Though Zonal Railways are following standard maintenance
practices for schedule attention (POH & ROH), there is a wide variation in the
consumption pattern of safety and vital items; the consumption is mainly guided
by their sanctioned AACs. So, there is a possibility of worn out components
remaining in service, thereby increasing the chances of failures.
The existing percentage replacement of the safety and vital items in ROH
depots and POH workshops have been collected from 16 ROH Depots and 5
Wagon Workshops over JR . The data collected has been compiled as Annexure-
A and Annexure-B respectively.The replacement percentage range for the items
attributable to Hot Axles, Train Partings and Brake Bindings are given as
under:-
Sick marking analysis of four Zonal Railways (SE, CR, SCR, & WR) for the last
three years has been studied and found that majority of failures are on following
account.
S. Percentage
Type of defects
No.
1 Brake gear 30.0
2 Wheel 24.2
3 CBC 20.3
4 Air Brake 13.4
5 Side Bearer 11.0
6 Centre Pivot 10.0
7 CTRB failures 8.1
POH.
A sample study of various items requiring renewal but allowed in service on
account of inadequacy of AAC has been done in Rayanapadu Workshops and
this shows that requisite provision of material is not being made in workshops.
Certain wear limits are provided on various components like Centre Pivots,
Pedestal Jaw, Bolster, Brake Gear Pins etc. but these wear limits should not be
applicable during POH for workshops because after having done the POH,
wagons are expected to give trouble free service at least up to next ROH. But
workshops are taking advantage of tolerance limits and allowing the wagons
with worn out components.
The committee had the discussions with CWMs, DY. CMEs of the workshops,
Sr. DMEs of the depots and Supervisors on the subject of must change items
during POH and ROH, observed the existing trend of material consumption in
workshops and ROH depots. Taking the experience of various officials involved
in maintenance of wagons and referring various technical pamphlets issued by
RDSO & CAM from time to time on the subject of wagon maintenance,
committee has made the following recommendations:
RECOMMENDATIONS:
A CASNUB BOGIE
A-1 SF Key nut bolt with During dismantling of wheel from bogie, it
washer is necessary to cut the bolt since it is tack
welded with nut. Therefore the committee
recommends 100% replacement of this item
during POH.
A-2 Split Pin 12 x 110 mm The split pins of Brake Shoe key are being
changed 100% in some depots as they are
getting distorted / damaged while taking out
the brake blocks. Hence 100 % replacement
is recommended during ROH.
A-3 CTRB Locking plate The Locking plates are being changed on
100% basis. While carrying out the UST of
Wheel sets, the locking plates are to be
removed and while doing so, tabs are
getting damaged or broken. Hence 100 %
replacement is recommended during ROH.
B CBC
B-1 Striker casting Wear This item is subjected to wear in service as
Plate it comes in contact with CBC Shank Wear
Plate. Some ROH depots are replacing the
item to the extent of 100 %. The worn out
component will have serious impact on
uncoupling of CBCs and it will also damage
CBC shank; it will cause ovality on the top
portion of Yoke Pin hole. Therefore the
committee recommends 100% replacement
of this item during ROH.
C Air Brake System
C-1 Dirt Collector Filter This is basically a non-metallic strainer and
of a small value. At present depots are
changing on condition basis and there is an
apprehension that dirt collectors are not at
all opened in depots during ROH. There are
many cases of DV malfunctioning and
subsequent brake bindings in service and the
filter is playing a major role. Therefore the
committee recommends 100% replacement
of this item during ROH so that it will be
compulsory on the part of the depot to open
the Dirt Collector.
C-2 Dirt Collector Washer These are the small value rubber items
(`O' Ring) perishable in nature and getting damaged
while opening the assemblies. Therefore the
C-3 Rubber gaskets
C-4 MU washers committee recommends 100% replacement
of this item during ROH.
C-5 AR Drain Plug leather These items are perishable in nature getting
washer damaged while opening the assemblies.
Therefore the committee recommends 100%
C-6 BC Drain Plug leather
replacement of this item during ROH
washer
D Tank wagons
D-1 Filling Pipe Joint Ring These are the rubber items perishable in
(B TPN) nature and getting damaged while opening
the assemblies. Therefore the committee
D-2 Man Hole Cover
recommends 100% replacement of this item
Sealing Ring.
during ROH.
S.
Description of item Justification for replacement
No.
A CASNUB BOGIE
A 1 - Side Frame
1. Pedestal Jaw Liners These items are subjected to wear in service
as they are continuously in contact with
adaptor and not expected to last beyond one
POH. The liners of suitable thickness are
required to be welded. Therefore the
committee recommends 100% replacement
of these items during POH. Committee also
recommends that no weld metal deposit
should be done on the pedestal jaw surfaces
to maintain the clearances as no machining is
done after welding. RDSO may explore the
possibility of liners in original design. The
smoothness of the surface is primarily
important.
2. SF Key nut bolt with During dismantling of wheel from bogie, it is
washer necessary to cut the bolt since it is tack
welded with nut. Therefore the committee
recommends 100% replacement of this item
during POH.
A-2 Bolster
I Land surface liner These items are subjected to wear in service
as they are continuously in contact with
adaptor and expected to last from POH to
Pocket slope liner POH. The liners of suitable thickness are
2
required to be welded. Therefore the
3 Rotation stop lug liner committee recommends 1000/0 replacement
of this item during POH.
A-3 Bogie Brake Gear
I Split Pin 12 x 110 mm The split pins of Brake Shoe key are being
changed 100% in some depots as they are
getting distorted / damaged while taking out
the brake blocks. Hence 100 % replacement
is recommended during POH.
A-4 CTRB Locking plate The Locking plates are being changed on
100% basis. While carrying out UST of the
Wheel sets, the locking plates are to be
removed and while doing so, tabs are getting
damaged or broken. Hence 100 %
replacement is recommended during POH.
A-5 Elastomeric pads It has been observed that many workshops
are replacing this item to the extent of 100%.
Being a rubber component, committee
recommends 100 % replacement of this item
during POH. However, the serviceable EM
Pads shall be given to divisions for
replacement during the course of train
examination.
B Draw and Buffing Gear Assembly
B-1 Knuckle Knuckle is subjected to wear on Nose,
Pulling lug area. Some workshops are
changing on 100% basis and released
serviceable material is given to divisions.
Knuckles are playing very important role in
coupling gear. In the present spurt of train
parting / uncoupling cases Knuckles might
be playing a vital role. Upgraded couplers
are being developed by RDSO as per WD-
70-BD-10. The committee therefore
recommends one time replacement of
indigenous knuckles with the upgraded
knuckles as per WD-70-BD-10. However,
serviceable knuckles shall be given to
divisions for replacement during train
examination.
B-2 CBC Lock Lock is subjected to wear on contact area
corresponding to Knuckle pulling lug and
curved surface. Committee has observed that
majority of the uncoupling cases are on
account of worn out Locks. Upgraded
couplers are being developed by RDSO as
per WD-70-BD-10.The committee therefore
recommends one time replacement of
indigenous CBC locks with the upgraded
CBC locks as per WD-70-BD-10. However,
serviceable locks shall be given to divisions
for replacement during train examination.
B-3 Rotary Lock Lift Mostly, the Anti-Creep Lug of Lock Lifter
Assembly Assembly is found in worn condition.
Moreover, the alignment is disturbed due to
riveting became loose in service Upgraded
couplers are being developed by RDSO as
per WD-70-BD-10.The committee therefore
recommends one time replacement of
indigenous lock lift assembly with the
upgraded lock lift assembly as per WD-70-
BD-10.However, serviceable assemblies
shall be given to divisions for replacement
during train examination.
B-4 Bearing Piece. The committee observed that consumption of
this item between workshops to workshop
varies from 3% to 33%. The item is
subjected to wear in service; the slot (17.5
mm x 17.5 mm) of bearing piece becomes
worn out in service and not holding the
Operating Handle in position. As a result the
operating handle along with Rotary Lock
Lift Assembly gets displaced from its
position thereby causing uncoupling of CBC.
The item is not expected to last beyond one
POH. The committee therefore recommends
100% replacement of this item. However,
serviceable bearing pieces shall be given to
divisions for replacement during train
examination.
B-5 Yoke Pin support plate This item is subjected to wear particularly
liner due to interaction of Yoke Pin's vertical
movement. The pin makes a dent mark on
the liner which is dangerous which restricts
the movement of the yoke pin resulting in
the breakage of Support plate rivets. The
item is not expected to last beyond one POH
cycle. The committee therefore recommends
100% replacement of this item.
B-6 Shank Wear Plate This item is subjected to wear in service as it
comes in contact with CBC Shank Wear
Plate. Some workshops are replacing the
item to the extent of 70%. The worn out
component will have serious impact on
uncoupling of CBCs and it will also damage
CBC shank. The life of the component is not
expected beyond one POH cycle. Therefore
the committee recommends 100%
replacement of this item during POH.
B-7 Striker Casting Wear This item is subjected to wear in service as it
Plate comes in contact with CBC Shank. Some
workshops are already replacing the item to
the extent of 100%. The worn out component
will have serious impact on uncoupling of
CBCs. The life of the component is not
expected beyond one POH cycle. Therefore
the committee recommends 100%
replacement of this item during POH.
C Air Brake System
C-1 Dirt Collector Filter This is basically a non-metallic strainer and
of a small value. At present workshops are
changing on condition basis. There are many
cases of DV malfunctioning in service and
the filter is playing a major role. The life of
the component is not expected beyond one
POH cycle. Therefore the committee
recommends 100% replacement of this item
during POH.
C-2 Dirt Collector Rubber
Washer (`O' Ring)
C-3 Rubber gaskets These are the rubber items perishable in
nature and getting damaged while opening
C-4 Rubber Seals of Cut off
the assemblies. The life of the items is not
Angle Cocks.
expected beyond one POH cycle. Therefore
C-5 MU washers the committee recommends 100%
C-6 Grip seals / Rubber replacement of this item during POH.
washers
C-7 AR Drain Plug leather These are items perishable in nature and
washer getting damaged while opening the
C-8 BC Drain Plug leather assemblies. Therefore the committee
recommends 100% replacement of this item
washer
during POH.
C-9 BP Air Hose This item is generally tested during POH for
leakage and bulging at 10 Kg/cm2 pressure
and about 50% rejection is there. Moreover,
there are large numbers of service failures.
Some workshops are changing 100% Being a
Rubber item; it is not expected to last beyond
one POH cycle. Therefore the committee
recommends 100% replacement of this item
during POH. However, serviceable hoses
shall be given to divisions for replacement
during train examination.
D Tank wagons
D-1 Filling Pipe Joint Ring These are the rubber items perishable in
(BTPN) nature and getting damaged while opening
D-2 Man Hole Cover the assemblies. Therefore the committee
Sealing Ring. recommends 100% replacement of this item
during POH.
The committee is of the opinion that with the replacement of the items
recommended above during ROH and POH, the reliability of freight stock will
improve significantly. However, there is a large variation in the consumption
pattern of the various items (given in Annexure A & B) during ROH and POH in
the Zonal Railways depending on their maintenance practices. Zonal Railways
may review the consumption of items and further rationalize the AAC of the
items at their end.
- --_---
- ---T-->
( ..... \ I
(P.A. Lamghare) (M. Amarendra) (S.K. Gupta)
Convener Member Member
(Shivendra Mohan) (R6ope rrvastv a)
Member Secretary
Anrexure-A
Material Consumption Pattern of ROH Depot
BKSC BSL
•O N 'i S
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DESCRIPTON
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1 Pedestal Jaw Liners 32% 28% 17% 2.66% 2.4% 2.5%
2 Pedestal Side Liners 32% 28% 17% 1.1% 0.95% 0.9%
3 SF Key nut bolt with washer 90% 80% 90% 56.1% 75.0% 26.3%
4 Land surface liner 32% 28% 17% 2.1% 2.7% 1.9%
5 Outer column gib liner 32% 28% 17% 5.9% 7.5% 5.5%
6 Inner column gib liner 32% 28% 17% 5.5% 5.6% 4.0%
7 Pocket slope liner 32% 28% 17% 14.3% 8.5% 7.6%
8 Rotation stop lug liner 32% 28% 17% 3.1% 2.7% 2.5%
9 Composite Brake Block 95% 95% 100% 100.0% 61.2% 75.1%
10 Brake Shoe Key 58% 56% 59% 57.3% 32.7% 22.0%
11 Split Pin 12 x 110 mm Nil Nil Nil 100.0% 100.0% 100.0%
12 CTRB Locking plate 100% 100% 100% 100.0% 100.0% 95.7%
13 Wedge Blocks - - - - - -
14 Center pivot (Bottom) - - - - -
15 Centre Pivot Top - - - - - -
16 Elastomeric pads 80% 48% 37% 58.2% 49.7% 33.5%
17 Metal bonded Rubber Pads 45% 45% 40% 46.4% 99.5% 29.0%
18 Polyurethane Rings of Side Bearer 5% 4% 9% 8.2% 3.4% 3.01%
19 Adaptor 2% 3% 3% 6.3% 11.5% 4.1%
20 Knuckle - - - - - -
21 Lock - - - - - -
22 Rotary Lock Lift Assembly 22% 24% 40% 50.0% 39.4% 45.7%
23 Bearing Piece. 6% 9% 19% 24.7% 76.4% 42.9%
24 Operating handle 39% 25% 40% 49.0% 75.9% 26.4%
25 Yoke Pin support plate liner - - - 55.2% 51.1% .7.5%
26 Front Stopper and back Stopper plates of CBC - - - - - -
27 Shank Wear Plate - - - 55.2% 51.1% 7.4%
28 Striker Casting Wear Plate 100% 100% 100% 55.2% 51.1% 12.2%
29 Dirt Collector Filter 0.6% 0.5% 0.5% 8.4% 7.6% 0.7%
30 Dirt Collector Rubber Washer (O' Ring) 16% 23% 20% 34.5% 30.7% 33.2%
31 Rubber gaskets 8% 5% 3% 43.1% 38.4% 41.5%
32 Rubber Seals of Cut off Angle Cocks. 8% 5% 3% 2.3% 3.3% 3.2%
33 MU washers 10% 10% 24% 84.8% 114.8% 67.6%
34 Grip seal washers Nil Nil Nil 1.9% 3.7% 25.2%
35 AR Drain Plug leather washer Nil Nil Nil 18.2% 29.3% 64.9%
36 BC Drain Plug leather washer Nil Nil Nil 18.2% 31.5% 64.9%
37 BP Air Hose 36% 33% 36% 10.4% 35.1% 16.6%
38 Filling Pipe Joint Ring (BTPN) Nil Nil Nil 64.5% 100.0% 100.0%
39 Man Hole Cover Sealing Ring. Nil Nil Nil 64.5% 97.5% 95.3%
Material Consumption Pattern of ROH Depot
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Material Consumption Pattern of ROH Depot
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1
Front Stopperandb ack
0 .2 5 0 .25 0 .25 2 .3 1 4 .27 1 .4 1
Stopperplatesof CBC
27 Shank WearPlate 100 25 86 12 .9 16 .55 17 21 82 107
28 Striker Casting Wear Plate 68 19 76 41 .95 39 .8 5 69 .57 57 93 112
29 Dirt Collector Filter 16 90 19 10 22
Dirt Col l ectorRubber
100 46 51 2 .58 8 .85 70 .8 5 10 22
Washer(` O' Ring)
31 Rubbergaskets 50 47 60 25 .22 35 .38 37 .78 27 60 56
Rubber Sealsof C utoff
26 19 19 33 .93 32 .24 39 .96 79 77 100
IV
An gle C ocks .
47 13
00
33 MUwashers 11 19 45 .52 32 .98
34 Gripseal washers
I
ARDrai n Plug leather 65 75
70
CA
washer
BC Drain Pl u g leather 70
60 60
O'N
1
washer l i
37 BP Air Hose 50 1 88 82 68 .57 82 .1 100 100 99 57
Filling Pipe Joint Ring
---)
6 .57 100 63 63
1
1
(BTPN)
Man Hole Cover Sealin g 19 .73 100 44 50
t
1
1
Ring .
MATERIAL CONSUMPTION PATTERNOFWORKSHOP(%Replacement
S ,TUDW JIBS
Description
No 20 10-2011 20 11-2012 20 12-2013 20 11 -20 12 201 1 -2012 I2012-20 13
Pedestal Jaw Liners 45 41 46 1 1 .14 9 .68 4.3
Pedestal Side Liners 0 .4 1 0 .22
I
1
e
1
SF Keynut boltwithwasher 88 46 25 97 .6 97 .5 62 .3
Land surface liner 18 16 24 8 .3 3 47 .33 8.79
..)
Outercol umngib liner 20 26 0.41 0.1 1
I
Innercolumngib liner
1
e
i
I
Pocketslope liner 25 43 30 48 34 .5
Rotationstop lug liner 15
LI)
2 .1 1 .12 0 .42
Composite Brake Block 1 00 71 72 97.6 83 .4 79 .9
VD
10 Brake Shoe Key 24 16 15 14
11 Split Pin 12x110 mm 100 100 100
I
12 CTRB Lockingpl ate 1 00 ' 100 100 100 1 00 100
13 Wedge B l ocks
(...0
0 .8 0 .54 0 .63
14 Centerpivot(Bottom) 27 24 38 25 24 23
15 Centre Pi vot Top 59 26 49 39 15 .6
16 Elastomericpads 100 98 100 100 97 .7 54 .1
17 Metal bonded Rubber Pads
I
PolyurethaneRingsof Side
Bearer 89 49 59 95 .2 5 100 8 .33
19 Adaptor 67 55 69 18 14 .5 1 .6 5
20 Knuckle 50 38 75 37.44 23 .74 29
71. Lock 17 16 4 .67 34 .24 0 .68
22 Rotary Lock LiftAssembl y 18 14 19 .1 9 .5 9 8 .68
23 Bearing Piece . 20 21 .87 19 .6
S JUDW JHS
No
Descri ption
2010-20 11 20 11 -201 2 201 2-2013 20 1 1 -20 12 1 20 11 -2012 20 12-20 13
24 Operatin g handle 46 45 13 47 43 .8 4 23 .7 5
O
25 YokePinsupportplateliner
C)
C.)
1
FrontStopperand back
N
01
N
1 .76 1 .2
i
t
1
Stopperplatesof CBC
27 Shank Wear Pl ate 100 90 49 47 22 .03 35 .75
28 StrikerCastingWear Plate 100
W
76 83 100 100 100
C)
C)
29 Dirt CollectorFilter 44 48 .2 4 8 .33
Dirt CollectorRubber
100
CD
la
100 100
Angle Cocks .
33 MUwashers 100 100 100 26 .7 29 35 .83
34 Gripseal washers 100 100 100
I
AR Drain Plug leather
100 100 100
L.rt
I
washer
BC DrainPlug leather
100 100 100
01
1
washer
37 BPAir Hose 19 31 29 4 9 .8 48 .22 62
Fillin gPipeJointRing
00
17
1
t
1
(BTPN)
Man Hole Cover S ealing
100
`C)
100 100
i
1
1
Ring.
Si ckM ark i n gAnalysi s(CR, SE R,SC R & WR)
-ft
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3
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*
=
detects
20 10-11 403 60 192992 7 106466 63 60 5880 13 90 27 17 97 10727 38 16 1 11 5 65 1 I 37 2 1 I 45621 I 1 1777 1 126 10 106482 I 30114
2 011-12 39 713 186 653 8 1006 37 7036 53 22 27 33 2 5 89 84 6747 367 3 1 059 746 2688 43208 12 13 9 1 2541 10056 5 25641
2012-13 197 01 8 9763 2 50734 3321 2841 1493 145 1 38 3 273 176 4 567 687 117 9 22 164 52 07 I 668 3 50668 13293
Total 99 774 4694097 257837 16717 14043 56 16 6757 2 19 20747 9 253 2741 2084 7 588 11 0993 29 123 31834 25 77 1 5 69048
4 .6 9 .0 0 ,3 35 .6 12 .7 3 .7 2 .2 12 .4 1 00.0
10,7 10 .1 0.3 2 6 .3 14 .3 4 .1 2 .9
Perc enta ge(Tot al excl ud i n g b ody, 10.5 100.0
d oor &Mi sc) 11 .2 10 ,9 0.3 24 .6 13 .3 4 .3 5 .2 8 .9 100 . 0
8.1 9.8 0.3 30 .0 13.4 4.0 3 .0 11 .0 100.0
_17
•