GOVERNMENT OF INDIA

h f MINISTRY OF RAILWAYS

(% $d RAILWAY BOARD)

No. 2009/Elect(TRS)/138/10 New Delhi, dated : 29.12.09

General Manager (Elect.)

Central Railway, Mumbai, Eastern Railway, Kolkata East Central Railway, Hajipur East Coast Railway, Bhubaneswar Northern Railway, New Delhi North Central Railway, Allahabad Southern Railway, Chennai South Central Railway, Secunderabad South Eastern Railway, Kolkata South East Central Railway, Bilaspur West Central Railway, Jabalpur Western Railway, Mumbai Chittaranjan Locomotive Works, Chittaranjan

Director General ( Elect.), RDSO , Lucknow

SUB : Allotment of POH/MTR and TM rewinding capacity for 2010-11 for Electric locomotives.

Ref : This office letter of even no. dated 03.11.09.

POH coordination meeting was held on 26.11.09 a t Electric Loco Workshop, Bhusawal, C. Rly. to allot POH capacity and TM rewinding targets to various workshops for the year 2010-11. This meeting was attended by officers from Zonal Railways, Workshops and Railway Board.

Minutes of the meeting along with capacity allotment to shops and TM rewinding targets are enclosed.

Calling in programme may be issued by the workshops and advised to all concerned accordingly.

DA : Asabove. K g- (Mohit Chandra)

Dir. Elect. Engg. (RS) Railway Board

e-mail : deers@rb.railnet.gov.in

Copy to :

(i) Chief Workshop Managers/Bhusaval (CR), Nasik Road (CR), Kancharapara (ER), and Dahod (WR).

(ii) CPM(Elect.), WRly, Vadodara, (ii) Dy.CEEs (POH) / Charbagh (NR), Perambur (SR) and Kharagpur (SER). (iii) Sr.DEE/TM Shop, Kanpur (NCR) & TATA (SER) (iv) Sr.DEE/ELS, Valsad (WR) (v) EDME(W), Railway Board.

Minutes of POH Co-ordination Meetino held at Electric locomotive workshop, Bhusawal, Central Railwav on 26.1 1.2OO9.

CWM/BSL welcomed Adviser(Elect)/ RS , Railway Board , DRM / Bhusawal and EDSE / RDSO, CEE (loco)/ CLW, CELEs / CWMs and other officers from different Zonal Railways. He apprised the group of the history, development and achievements of BSL workshop in the field of electric locos since it was established.

Formal inauguration of the meeting took place by ignition of 'Deep Jyoti' by Adv.L(RS) & DRM/BSL.

Address by Adv.URS):

Complemented CWMIBSL for efforts made in achieving the highest ever outturn in 2008-09. This needs to be further increased and maintained along with quality for improving reliability of electric locos.

Complimented Zonal Railways for satisfactory performance with respect to equipment failures and punctuality performance during 2008-09 and for the period April to Sep'09. However, the above should not be a cause of complacency as target ahead are further challenging. Also, in absolute terms there has been a drastic increase in the number of trains losing punctuality everyday. These cases might not be getting reported earlier but are cause of loco defects which needs to be reduced. Each & every case need to be examined. CELEs should go into the depth to ascertain the reasons and take corrective action.

IR is passing through difficult stage as large no. of accidents have taken place in past three months. There has been cases where drivers have been responsible or contributory. Besides concentrating on the maintenance aspects of electric locos, there is need to gear up and address these safety issues as well. Advancements in technology and availability of systems like TPWS , AWS etc. for the aid of drivers should be welcomed. Communication between Driver & Guard may be streamlined and drivers should be closely monitored through rigorous footplates etc.

Though the purpose of meeting is allocations of capacity to workshops for POH and re-winding, there is need to review the role of the workshops. The workshops which used to play a back seat role are now required to gear up for regular requirements of sheds and play an active role so that the overall efficiency of the system is improved. During the meeting while discussing the regular agenda items, this aspect needs to be kept in mind as well.

Discussions and decisions taken on Aaenda items:

1.0 Periodic Overhauline: (POH/RC/MTR):

Status of progress of POH/POH+RC/ MTR was reviewed:

Work Shop

BSL

KPA

Target 09- 10

PER

KGP

PO H POH+RC

PO H

DHD

All the workshops, though presently lagging behind the proportionate target for POH or POH+RC up t o Sep109, confirmed that the targets advised by Board shall be achieved by year end.

Prop. Target U ~ t o Se~t'O9

PO H POH+RC

POH POH+RC

1

The workshops to review their processes and plan outsourcing of activities to generate spare manpower for expediting schedules for reducing the average time taken for POH and POH+RC and bring them within the norms.

Actual u ~ t o Se~t'O9

96 2 1 50

POH+RC POH MTR 56 28 27 I

Time taken for POH of 3-phase locos to be brought down to 60 days for this year CWM'BSL i.e. 2009-10 and 50 days from 2010-11 onwards.

41 12 51 13

All the workshops to ensure strict adherence to the specified work schedule of POH including cleaning of cable trays/ ducts, redressing of control cables and their numbering, opening of Power cable cleats to check the condition of cables, overhauling CBC etc.

48 10.5 2 5

3 4

There has been an improvement in the failures reported within first 100 days of POH of electric locos. All the workshops have registered improvement except PER as under:

46 10 2 6

20.5 6

25.5 6.5

19 5

3 1 5

- -

1.5 2

-

1 3

Total failures up to Sept109 Out-turn up to Sept109 Failure per loco outturn in first 100 days (09-10) Failure per loco outturn in first 100 days (08-09)

Total

164 188

0.87

1.19

POH workshops BSL 57 56

1.02

1.47

PER 14 24

0.58

0.34

KPA 43 36

1.19

1.57

KGP 2 5 36

0.69

1.0

CB 7 6

1.17

1.59

DHD 18 30

0.60

1.08

0

Sr.EDSE/ RDSO

0

Sr.EDSE/ RDSO

Sr.EDSE/ RDSO

Though the failure rate of electric locos POHed at PER continue to be the lowest, there has been overall deterioration which has been mainly because of Pneumatics and EMC/EPCs . PER informed of having started blowing of pipelines and also the overhauling of Air dryer which was not being done earlier and confirmed of delivering improved quality products in future.

NCR & WCR reported that the quality of POH at CB workshop is not up to the mark which is using non-standard material and not changing VCB kits, cable cleats, damaged cables and air flow relays etc. CELE / NR should audit the quality and ensure that material from approved sources only is used and 100% must change items are replaced.

Workshops reported that customer railways were not giving feedback on failures of off-POHed locos. They are not serious to attend the customer feedback meetings organized by POH shops for interaction for improving quality.

Zonal Railways to furnish the information /feedback to workshops timely. Customer feedback meetings must be attended at least by an officer along with one supervisor from each customer shed.

All the workshops to develop an online feedback module and issue login & password to all the Zonal Railways to enter failure details on off POH locos. CELEs to ensure the compliance by 31.12.09 and report to Board.

Workshops should ensure a minimum 98% compliance of Must Changed Items as laid down in RDSO TC no. 21. Any deviation to the target can only be permitted by written permission of concerned CELE. Concerned Railways are also advised to check the level of compliance of MUST CHANGE items.

Though thin walled cables are being used by workshops and CLW, EPDM cable cleats are not being used. RDSO to re-view the performance of EPDM cable cleats provided on locos at TKD & CNB and also on the locos being provided by BHEL and advise Zonal Rlys & CLW for provision during POH / MTR and on new production. This should be done by 31.12.09

Railways expressed difficulties in rehabilitation of tap changers due to discrepancies in maintenance kits. A committee comprising of EDSEIRDSO (Convener), CELE/ER and CELEIWR was nominated to standardize the description of items and freezing kits for AOH, IOH & POH to overcome the difficulties in rehabilitation of tap changers. RDSO should submit report to Board by 31.12.09.

RDSO informed of having collected feedback on 'Must change' items from all the Zonal Railways for review of TC-21 i.e. list of 'Must change' items. There does not appear to be significant change in the existing list. RDSO shall issue revised list by 15.12.09.

Proposed allotment of POH, POH+RC & MTR to various workshops for 2010-11 was discussed and final allotment is enclosed at Annex A. List of loco nos. for MTR is enclosed at Annex 8.

Tentative allotment of POH, RC & MTR for 2010-11 and 2010-12 is placed at Annex C.

2.0 Traction Motor Rewinding

Detailed allotment of TM rewinding for various workshops was discussed and final allotment is enclosed as Annex D. Considering vide variation in cycle time taken for rewinding HS 15250A armatures i.e.

CEE/CR 52 days at TMW / NKRD against 35 days at TMS / CNB and increase in arising of HS 15250A armatures, a committee comprising of CWMINKRD (Convener), CELE / NCR and SrDEE/TMS/ CNB is nominated to audit the rewinding processes at TMW / NKRD and TMS/ CNB and submit report through CEE/CR by 31.01.10.

TM shops to strictly ensure purchase of seasoned commutator assembly with steel parts Sr.EDSE/ only in compliance of instructions already issued by RDSO. RDSO to reiterate the RDSO instructions.

TMS / CNB should develop necessary infrastructure for undertaking the rewinding of Traction Motor stators and rotors for WAG9 / WAP7 three phase locos so as to be ready by 2011-12 to take up the work.

3.0 Other issues

3.1 Supply of wheel sets for conventional locos:

(i) Sanctions available up to 2006-07 (Board letter no. 2008/Elect(TRS)/720/1 dated 22.12.08)

Since, CLW has not been in a position to manufacture and supply wheel sets to Zonal Railways against various RSP sanctions, Board had advised workshops to undertake the work. The status of pending supplies now stands as under:

Wlshop

KPA

KPA

(ii) Sanctions available during 2007-08 and 2008-09 (Board letter no. 2008/Elect(TRS)/720/1 dated 22.12.08)

KGP

CB*

Type Of

wheel

Conv.

Conv.

Conv.

Conv.

Distribution among workshops

No. of wheel sets to be supplied

60

10

WR WCR Total

36

23

No. of wheel sets supplied

60

16 67

Supply Pending

03 ready wheel sets yet to be lifted by ECoR 9 to be supplied to WCR. Target - Mar'lO

33 SECR (3) To be supplied to NR(19) & NCR(4). Target - Sep'lO

24 128

6 - 6 1 2 3 96

43 291 59 80

12 43 63 34 30 25

(DHD) , 1 6 in JuI'lO (KGP) Jun'lO

Jun'lO

3.2 Supplv of wheel sets for Three Phase Locos:

(i) Sanctions available During 2007-08 and 2008-09 (Board letter no 2008/Elect.(TRS)/720/1 dt 15.09.08)

(ii) Sanctions available during 2009-10 (Board letter no. 2008/Elect(TRS)/720/1 dated 04.08.09)

Railwa

Y

C R ECR NR SCR SECR WCR

WAG9

2 7 24

2 7 18 2 1 117

Railway

CR ECR NR

3.3 Conversion of Plain suspension bearing to Roller suspension bearing:

WAP7

06 41

47

WAG9

SR SC R SECR WCR

The work of conversion of plain suspension bearing to roller suspension bearing on TAO motored locos is slow. Out of the sanctioned 64 WAP-1 locos to NR and SR, only two locomotive have been modified so far. Both the railways should expedite the work. Few WAP-1 locos are due for MTR during the year 2009-10. Respective railway may transfer corresponding sanctions to Dahod which shall ensure conversion during MTR. DHD workshop should co-ordinate and plan material so as to turn out WAP-1 locomotives after conversion only.

10 12

Further, POH workshops gave the following target dates for cut-in of TAOchi conversion on WAG5 locos

WAP5

12

12

WAP7

6 12 10

12

Total

2 7 30 53 27 18 21 176

WAP5

6

Work shop BSL KG P

( DHD for MTR I Already cut-in.

- 5 -

10 12 12

Cut-in dates 1" Jan'10 lStJan'10

KPA PER C B

undertake the work

BSL KPA BSL KPA KPA BS L

Total

BSL KPA BSL

6 6 12 10

1" Apt10 1'' Apr'lO No commitment

Targets given by work shops

Feb'lO for starting delivery

Workshop to undertake

the work

BSL KPA KPA BSL

Targets given by work shops

Oct'10 for starting delivery

3.4 Crew friendly Cab modification:

Sr.EDSE/ RDSO

Sr.EDSE/ RDSO

Workshops have not been complying fully to the revised instructions issued by RDSO vide letter no. EL/3.1.10/1 dated 27.11.08 for cab modification during POH. CWM / DyCEEs of the workshops to ensure 100 % compliance. No loco to be turned out after POH without crew friendly cab modification from lStJan' 10 onwards.

3.5 PU painting:

CLW and all the workshops undertaking POH of electric locos have now started PU painting on electric locos. Considering the need to standardize quality, a committee comprising of DSE(CS) /RDSO (Convener), Sr.DEE(TRS)/GZB/NR and Sr.DEE(TRS)/LGD/SCR has been nominated to audit the infrastructure and processes of PU painting in different workshops/CLW along with quality of paint being used and submit action plan to improve the quality further by 31.12.09.

As regards periodicity, Zonal Railways were of the view that periodicity prescribed by RDSO i.e. POH to POH is too long. In such a long period, which is 6 years for conventional coaching locos and 9 years for freight, PU painting would loose its gloss and may not last. Some of the Railways have send their observationsand views to RDSO. RDSO to review and advise Zonal Railways accordingly.

3.6 Uniform costing of POH of Electric Locos :

The average cost of POH/POH+RC/MTR for various workshops has been as under:

I MTR 1 105 1

Activity PO H

There exists wide variation in costing of POH in different workshops. The average Dy.CEE/PER cost of POH/ POH+RC of PER workshop is extremely high as compared to other CEE/SR workshops. DyCEE/PER and CELE / SR were advised to review the costing methodology

in association with finance.

CWMIBSL informed that suitable modifications are being undertaken in existing software to bring the costing system in line with the directions issued by Rly

CWM/BSL Board. The revised software shall be circulated to all workshops for CEE/CR implementation by 31.12.09 . However, the software for integration with AFRES /

PRIME shall be got developed by 01.04.10.

BSL 64.82

KPA 56.36

PER 89.22

KGP 53.58

CB 56.66

DHD 58

3.7 Setting up of new POH workshop at Dabhoi:

CEE/WR CPM (Elect.)/ Dabhoi apprised of the status of progress of the new POH workshop to be set up at Dabhoi with State of Art facilities to under take POH of 100 electric locos per annum. WRly has processed the work through a composite advertised tender i.e. including civil, electrical, S&T works and M&P as advised by Board. Proposal for NIT duly vetted by associate finance is with WRly HQ for GM's approval which is likely to be cleared by 15.12.09.

c ~ M ( E ~ ~ ~ ~ . ) / CPM (Elect.)/Dabhoi was advised to make a presentation to AML/ML in Rly Board

Dabhoi on the project details in Dec'09.

List of participants in the POH coordination meetina at

Bhusawal on 26th November 2009.

I 1. I Shri. Kul Bhushan I Adv. L (RS) I Rly.Bd. I Sn

1 4. 1 Shri Sanjive Swaroop I EDSEIRDSO I RDSO I

Name

2.

3.

1 6. 1 Shri. R.P.Sharma I CWM/ELW/BSL I CR I

Designation

Shri. Mohit Chandra

Shri. Sushil kumar

I I I

Rly.

5.

I I I

8. 1 Shri. S.K.Agarwal I CWMINKRD I CR

DEE(RS)

AEE/RS

I I

I I I

9. 1 Shri. M.K.Singhal I CWM/KPA I ER 1

Rly.Bd.

Rly.Bd.

Shri. P.N.Rai I CEE/Loco

7.

C LW

Shri Sunil Mathur

10.

11.

12.

13.

1 16. / Shri. Nasimuddin I CELE I NCR I

CELE

Shri. S.Kumar

Shri. S.K.Singh

14.

15.

CR

Shri. Rajeev Agrawal

Shri. S.S.Purohit

D~.CEE/P&D/KPA

CELE

Shri. V.P. Singh

Shri. Rajan Saksena

I I I

1 19. / ShriSameer Dighe ( Dy.CEE/LW/PER I SR I

ER

E R

CELE

Sr.DEE/TRS/VSKP

17. 1 Shri. Anuj Vyas I Sr.DEE/TMS/CNB I I I

ECR

ECoR

CELE

Dy .CEE/POH/CB

NCR

18.

NR

NR

I I I

1 24. 1 Shri. Sanjay Agarwal I CWMIDHD I WR I

Shri. Sushil Vavre

20.

21.

22.

23.

CELE

I Shri. B. Panda

Shri. K.K. Patro

Shri. R.K.Tiwari

I I I

S R

SCR Shri. S.K.Agarwa1

25.

26.

27.

CELE

CELE

Dy.CEE/ERS-POH/KGP

CELE

SER

SER

SECR

Shri V.H.Chandorkar

Shri. Sameer Saigal

WR Shri. V.K.Tirpathi CELE

CPM/EL/BRC

Dy.CEE/Loco

WR

WCR

ANNEXURE-A PROPOSED SHOP CAPACITY /ALLOTMENT FOR POHlMTR OF ELECTRICmOS FOR 2010-11.

m a * e h-4 FOR MOM.6

Annexture-B List of MTR proposed for the vear 2010-11

SN I RLY 1 LOCO NO I TYPE SHED

1 I SECR I 23361 I WAGS I BIA

2 1 NCR I 23381 WAGSH JHS 23376 WAG5H 23378 WAG5H

SECR 23388 WAG5 SER 23387 WAG5H BNDM

7 WCR 23384 WAGS TKD 8 23392 I WAG5 I BI A 9 NCR I 23419 WAGSH JHS

I 10 I SER I 23417 I WAG5H I BND- 11

12 13 14

1 18 1 WR 1 23428 WAG5H 1 BRCY

15 16 17

19 1 E R I 23462 I WAG5H I ASN 20 I SECR I 23457 WAG5 B IA

SER SER S R NR

2 1 I SER I 23469 1 WAG5 I TATA I

NR SECR WR

22 1 SER 1 23470 1 WAG5H I BNDM I

23418 23420 22011 22013 22014 23448 23427

WAG5H WAG5H WAPl WAPl

23 24

25

29 I WCR I 23486 1 WAG5 ET I

BNDM BNDM ELSIAIJ

GZB WAPl WAG5

WAGSH

2 6 2 7 28

GZB BIA

BRCY

SCR SER SER WCR SCR SR

3 1 3 2 3 3

1 37 1 CR 1 23558 1 WAG5 I BSL 1

23475 23473 23481

34 35 36

23485 23487 23480

WR CR E R

1 4 1 1 NR I 22020 1 WAPl I GZB I

WAG5 WAGSH WAG5H

CR SR CR

38 39 40

42 1 WCR I 23561 I WAGS I ET 43 1 WCR I 23579 WAG5 ET 1

BZA BNDM BNDM

WAG5 WAG5

WAGSH

23506 23534 23525

1 44 1 NR 1 22023 1 WAPl 1 GZB I

ET BZA

ELS/AlJ

23536 23537 23529

S R ECoR

E R

CR 1 23588 WAG5 I BSL

WAG5 WAG5 WAGS

47 1 ER I 23589 I WAG5H I ASN 48 1 ER 23592 WAG5H ASN 1

BRCY BSL ASN

WAG5 WAG5H WAG5

22018 23505 23562

BSL E LSIAIJ

BSL

WAP-1 WAG5

WAG5H

49 1 ECoR I 23607

- - ~ ~

53 I SER 1 23643 I WAGSH I BNDM

E LS/AJJ VSKP AS N

50 5 1 5 2

WAG5 VSKP

N R E R

NCR

22025 23628 24020

WAPl WAGS

WAG5H

GZB ASN JHS

TENTATIVE ALLOTMENT FOR POH/MTR OF ELECTRIC LOCOS FOR 2011-12 & 2012-13

Shop

BSL

KPA

CB

PER

KGP

DHD

TY Pe

WAM4

WAG5

WAG7

WAPl

WAP4

. WAP5

WAG9

WAP7

WCAMl

WCAM2

WCAM3

Total

WAM4

WAG5

WAG7

WAP4

Total

WAG5

WAG7

Total

WAM4

WAG5

WAG7

WAPl

WAP4

Total

WAM4

WAG5

WAG7

WAP4

Total

WAPl

WAG5

WAG7

Total

Grand Total

POH

5

10

11

4

38

5

4

9

2

26

114

4

20

30

54

1

13

14

12

14

4

2 6

56

9

8

5

26

48

0

286

POH

9

14

2 5

16

9

7

11

1

14

106

3

2

2 3

36

64

1

13

14

5

12

4

2 7

48

15

13

9

12

49

0

281

2011-12

POH+RC

3

3

11

2

1

14

2

2

1

2

3

6

6

0

28

2012-13

POH+RC

4

4

2

4

6

2

2

9

1

10

1

7

8

0

30

MTR

0

12

42

48

48

TOTAL

5

13

11

4

38

0

5

4

9

2

26

117

4

11

22

31

68

3

13

16

12

15

0

6

26

59

9

14

5

26

54

12

42

48

362

MTR

3

38

13

54

54

TOTAL

0

13

14

0

25

16

9

7

11

1

14

110

3

4

27

36

70

3

13

16

5

2 1

4

1

27

58

15

14

16

12

57

3

38

13

54

365

AnnexturcD TENTATIVE SHOP CAPACITY ALLOTMENT OF TRACTION MOTOR REWINDING FOR 2010-11. l P r a m e d bv Rk.1

WCR I 110 1 30 I 30 I 50 I I I 110 TOTAL 1 575 1 219 1 125 1 85 I 110 I 36 1 575

ARISING FOR 2010-11

20 I I I 20 I 1 I 20 WCR I 0 0

TOTAL ] 413 1 55 1 273 ( 85 I 0 I 0 1 413

AUOTMENT FOR 2010-11

NKRD 1 KPA I CNB 1 TATA I BL I TOTAL

ARISING FOR ALLOTMENT FOR 2010-11 RAILWAY I I 2010-11 I NKRD I KPA I CNB 1 TATA 1 TOTAL

STATOR (6FXll

WAP5 TM ROTOR (6FXA

NR WAP7 TM

STATOR (6FW

Capacity for rewlndlng

Due to limited capaclty of TMW /Naslk Road. The balance work to be got done through trade.

18 30 30 30 36

CR

EcR

G9 STATOR G9 ROTOR

EMU STATOR G9IP7STATOR G9/P7 ROTOR

WAPS TM

235 12 15 30 28

30

0 8

2 6

0 243 12 15 30 30 36