quality audit [02-2011] corrosion repair of coaching stock at llh on 18.01.11

QA 02/2011 CORROSION REPAIR, COACHING STOCK, LILUAH, EASTERN RAILWAY PAGE 1 of 21

QUALITY AUDIT REPORT

CORROSION REPAIR OF COACHING STOCK

NO. 02/2011

CARRIAGE & WAGON WORKSHOP

EASTERN RAILWAY, LILUAH

JANUARY 2011

QUALITY ASSURANCE (MECHANICAL) DIRECTORATE RESEARCH DESIGNS & STANDARDS ORGANISATION

MANAK NAGAR, LUCKNOW-226 011


QUALITY AUDIT REPORT

CORROSION REPAIR OF COACHING STOCK

CARRIAGE & WAGON WORKSHOP, LILUAH

As per Railway Board’s directives vide Letter No. 2009/M(W)/814/35/Safety, dated

11.11.2010, Quality audit of Liluah Workshop has been carried out by Shri M.A.

Alam, Director/I&L/Kolkata and his team on 18th January 2011. The quality audit was

done in accordance with Coaching Maintenance Manual, Technical pamphlet No. C-

7602 Rev.1 after preparing the check list. Shri A.K.Pandey, CWM/LLH and Shri

Rishikesh Prasad, Dy.CME/Mfg/LLH had given all assistance to facilitate quality

audit. During audit AWM/C&W/LLH along with SSE and JE of Workshop

accompanied RDSO team.

Observations:

1. Thick sections required in corrosion repairs (5mm or more) are not grit/shot

blasted.

2. Painting of head stock with M&C/PCN/123/2006 for high performance

anticorrosion epoxy coating is not ensured. This item has not been stocked

and procured by shop.

3. Shop is not carrying out MIG welding for corrosion repair of coaches.

4. Shop has no inverter base machine for welding.

5. Shop is not using correct electrode as recommended by RDSO for corrosion

attention of coaches. Shop is using A2 class electrode instead of class D

electrode for IRS M-41 steel. Even for SS welding, shop is using M-1 class

electrode instead of M-2 class electrode. Shop is now reported procuring M-2

class electrode.


6. Shop has no facility for shower testing to check roof leakage. Roof leakage

attention is not adequate and roof is attended on condition basis (on the basis

of open line report only)

7. Inner head stock is replaced when thickness is less than 6 mm or on condition

basis. Similarly, Outer headstock is replaced when thickness is less than 4

mm or on condition basis. LLH shop is carrying out replacement of outer head

stock only when outer head stock is required to be replaced. However when

inner head stock is to be replaced, then inner head stock, outer head stock

and stiffeners are replaced. Items are replaced separately. Shop has recently

started changing of complete assembly consisting of outer & inner head stock

and stiffeners in some coaches. These are assembled, welded and fitted in

coach as a set. Status of fitment of assembled head stocks during last

three months is as under:

Nov’10 – 1 set Dec’10 – 1 set Jan’11 – 3 sets

LLH shop is carrying out replacement of approx 40 inner head stock for which

40 sets assembled inner & outer head stock are to be replaced. Facility and

infrastructure is yet to be developed to carry out this activity.

8. Welders are deputed for training at BTC attached to workshop for training.

Samples are prepared as stipulated in IS 7310 Pt I, and finally certified by

CMT/LLH. Records have been checked. Few certificates were checked and

observed that all samples prepared for certification are not being checked in

accordance with IS 7310 Pt I provision.

9. Out of 262 welders deployed in M shop and SCR shop for corrosion attention,

104 welders are yet to be certified by CMT. Up-gradation of 104 welders to

higher grade is yet to be done.

10. For light corrosion, quality of cleaning to scrap off the rust to bare metal and

re-paint is not adequate.

11. To prevent corrosion of battery box frames, hot galvanized battery box is not

used. Battery box is fitted with FRP trays only.


12. Quantum of providing SS inlays with PVC flooring is not adequate. Shop is

providing SS inlays with PVC flooring in coaches only against RSP provision

and status for provision of SS inlays during last three years is as under: –

2008 – 09: 02 nos 2009 – 10: 14 nos 2010 – 11: 19 nos.

13. Documentation for corrosion attention is not adequate. Shop is not strictly

maintaining corrosion diagram. Details of corrosion attention with diagram

and check list for each coach is not maintained at LLH shop.


Quality Assurance Directorate (Mechanical) RDSO Lucknow

Check Sheet for Quality Audit of Corrosion Repair of the Coaches during POH attention at shop

(Based on CAMTECH Maintenance Manual for BG coaches of ICF Design and Technical pamphlate No. 7602/ Rev 1)

While doing the audit, ensure that the below mentioned activities are carried out as specified in the maintenance manual. Wherever the activities are not performed correctly indicate the method adopted or the nature of non-compliance.

SN REQUIREMENTS CLAUSE OBSERVATIONS

1 Ensure that the coaches are given POH at the specified intervals.

103 POH attention is being given at 18 months interval for conventional coaches and 36 months interval for LHB coaches.

2 Ensure that the coach body is lifted off the bogies using two 25t cranes each or by four lifting jacks of 15t each and coach body is not lifted from one end only.

105c 105d

Coach body is lifted by two crane in lifting shop and by hydraulic jacks in M shop and SCR Shop (Corrosion repair shops): Liftind shop has following cranes: 25 T – 4 nos. 40 T – 2 nos.

3 Ensure that the entire under frame is cleaned of dust, rust, scales etc. from the underneath through turn under holes.

105f Partially ensured. Cleaning is not adequate.

4 Ensure that the portion, which gets covered and becomes difficult to reach after the coach is lowered, is painted with one coat of anti-corrosive paint before lowering the coach body.

105g This is being ensured in lifting shop.

5 The system exists to inspect and repair of under frame members after the coach body is lifted off the bogies and placed on trestles.

202a Inspection is being carried out in lifting bay jointly by inspection wing and shop supervisor. On the basis of inspection, coach is categorized for attention as under: 1. Light corrosion (less than 70.4 man hrs) 2. Light medium corrosion (> 70.4 and < 500 man –hrs) 3. Medium corrosion (.501-1000 man hrs) 4. Heavy corrosion ( > 1000 man hrs) Status of corrosion attention from



July’10 to Dec’10 is as enclosed as annexure.

6 The underframe members should be thoroughly inspected for locating cracked/ bent/ corroded members. Corrosion is indicated by flaking of paint, flaking of metal, pitting and scale formation. Components like sole bar and trough floor which are not visible from both sides should be examined by tapping with a spiked hammer. Proper illumination will be required to carryout the check. A component will require repair/ replacement, if it has lost more than 20% of its thickness.

202c (i) System exists to check the corroded members and other defects.

7 Particular attention should be paid to the more vulnerable members and locations listed below:- Sole bar, body pillars, turn

under and tubular frame/ trough floor below lavatories in all types of coaches and the luggage compartments of all SLRs and parcel vans.

Sole bars, body pillars, turn under and pillars above lifting pads

Sole bars and pillars behind the sliding door pockets of SLRs and parcel vans.

Sole bars, pillars and turn under at the door corners.

Head stock. Sole bars, pillars and turn

under near coach body bolster.

202 c (ii) To check the corrosion arising of vulnerable location such as sole bar, body pillars, tubular frame and turn under, side body panel is cut through oxy-cutting of recommended size. For checking corrosion arising of trough floors, floor board is removed and trough floor is examined in the suspected corrosion area.

7 Procedure for inspection of underframe members for corrosion attention in case of vulnerable and not so -vulnerable locations should be followed as given in RDSO technical pamphlet No. 7602 (Rev.1)

202d This is being ensured.



i) Sole bar, body pillar and turn under under at lavatory area Examine visually

supplemented by tapping with a spiked hammer sole bars, body pillars and turn under in the bays under and adjoining lavatories from below the coach and through the elongated holes in the turn under after removing the accumulated dirt and cleaning the surface through then holes. If corrosion is suspected at places in the coaches without elongated holes in the turn under, a 100 mm diameter hole should be cut in the bottom of the turn under without damaging the pillars for examining the inside.

If incidence of corrosion is noticed in the bottom half of the sole bar, the trough floor should be cut to a width of 300 mm and requisite length for examination of inside top half.

If heavy corrosion is noticed, the side wall should be cut to a height of 500 mm. from the bottom of turn under covering sufficient length and all the exposed parts, after scraping and cleaning, should be examined to determine the extent of corrosion.

ii) Sole bar, turn under and pillars above the lifting pads Examine the above members

in the same manner as described para 202d (i )

This is being ensured. To examine corrosion, oxy-cut as recommended is done. This is being ensured. To examine corrosion, oxy-cut as recommended is done. This is being ensured. To examine corrosion, oxy-cut as recommended is done. This is being ensured. To examine corrosion, oxy-cut as recommended is done.



If signs of corrosion are noticed, the side wall sheet above the lifting pads should be cut to a height of 500 mm above the turn under and to a length of half metre, on either side of lifting pads. Scrape the structural members, clean and examine minutely to ascertain the extent of corrosion.

iii) Sole bar and pillars at door corners Examine the above

locations visually. If corrosion is noticed, cut the turn under to a width of half metre from the door corner. Remove accumulated dust. Structural members should be thoroughly scraped, cleaned and examined to assess the extent of corrosion.

iv) Sole bar, turn under and body pillars at locations other than those described above Examine visible portion of

sole bar through the elongated holes of turn under and from bottom of the underframe.

Remove the accumulated dust in the turn under through elongated holes and scrape structural members to the extent possible. If corrosion is noticed, side wall sheet in the area of corrosion should be cut to a height of 450 mm. from the bottom of turn under covering sufficient length for thorough examination.

v) Head stock Examine visually inner head

stock, outer head stock, stiffening immediately

This is being ensured. To examine corrosion, oxy-cut as recommended is done. Accumulated dust is removed and structural member is cleaned before examination to assess the extent of corrosion This is being ensured. To examine corrosion, oxy-cut as recommended is done. This is being ensured. To examine corrosion, oxy-cut as recommended is done. Inner head stocks, outer head stock, stiffening are examined for corrosion attention.



behind the buffers and the junction of the sole bar at the head stock for incidence of corrosion.

Examine carefully the base of buffer assembly as corrosion has been primarily noticed at this location.

Examine carefully the buffer base of head stock by chalk test or sound test for cracks and dents. Buffer fixing holes should not be elongated and no minor cracks to be allowed. Replace head stock if the wear is more than 4 mm i.e. when the thickness is below 4 mm.

Base of buffer assembly is examined for corrosion arising. Chalk test is not done. Only sound test is done. Shop has facility for pressing single piece inner & outer head stock through press brake. Inner head stock is replaced when thick is less than 6 mm or on condition basis. Similarly, Outer head is replaced when thickness is less than 4 mm or on condition basis. LLH shop is carrying out replacement of outer head stock only in case only outer head stock is required to be replaced. In case inner head stock is to be replaced then inner head stock, outer head stock and stiffeners are replaced in set. Complete assembly consisting of outer & inner head stock and stiffeners are assembled, welded and fitted in coach as a set. However, this has been started recently and status of last three months is as under: Nov’10 – 1 set Dec’10 – 1 set Jan’11 – 3 sets LLH shop is carrying out replacement of approx 40 inner head stock for which 40 sets assembled inner & outer head stock are to be replaced. Facility and infrastructure are yet to be developed to carry out this activity.



vi) Trough floor Examine the trough floor in

the bays adjoining the lavatories and under the luggage compartments of SLRs and parcel vans from below for signs of corrosion, supplemented by tapping with a spiked hammer.

If signs of corrosion are noticed in the above examination, the part should be thoroughly cleaned by scraping and an intensive inspection should be carried out to detect the extent of corrosion in the trough floor.

Magnesium oxychloride or plywood/compreg with PVC overlay flooring in the lavatories and bays adjacent to lavatories of all coaches over six years old should be broken and trough floor thoroughly examined for incidence of corrosion.

vii) Tubular frame below lavatories Examine visually the tubes

and joints for incidence of corrosion.

Corroded tubes shall be replaced. If corrosion is extreme, entire tubular frame should be replaced..

This is being ensured. Shop has MC of both SS trough floor & IRS M-41 trough floor. SS trough floor: MC – 4 coach sets (100 pc) IRS M-41 trough floor: MC – 8 coach sets (200 nos) This is being ensured. This is being done. Compreque with PVC overlay is provided. In addition for non AC coaches, epoxy flooring of floor-koat is provided in lavatory area, door way and gangway area. This is being ensured. This is being ensured.

8 Corrosion repairs to Underframe Members i) Corrosion repairs should be carried out as per instructions laid down in RDSO Technical Pamphlet nos. C-7602 (rev.1) for ICF coaches. It is essential to use corrosion resistant steel sheets for corrosion repairs of coaches.

202 e LLH shop is following guidelines for corrosion repair as stipulated in technical pamphlet nos. C-7602 (rev.1) for ICF coaches. Corton steel IRS M – 41 is used for corrosion attention.



Welding electrodes and paints should be of the prescribed quality conforming to the relevant IS/ IRS specifications. Corrosion resistant steel

sheet for trough floor, pillars, side-wall and roof to IRS M.41 - 97.

Electrode of approved brands.

Paints: Red oxide zinc

chromate primer – IS 2074-62. Bituminous anticorrosive solution to IRS P30-96, solution type, brushing quality.

ii) Where the corrosion noticed is of a very minor nature and has just started, there is no need to renew the parts. In those areas, the paint and the rust should be thoroughly cleaned to reach the bare metal and the surface treated with two coats of red oxide zinc chromate primer. In addition, underframe members should be given two coats of bituminous solution. Where the corrosion repairs are carried out on the underframe or its paint coat is damaged, the underframe should be painted with two coats of red oxide zinc chromate primer followed by the four coat system of anti-corrosive bituminous paint. For carrying out corrosion

SS trough floor is also used in addition to IRSM-41 trough floor. For IRS M -41 grade, recommended Electrode is RDSO class ‘D’ or AWS 8018. However, LLH shop is using RDSO class A2 electrode for corrosion attention. Consumption of electrode is enclosed as annexure II. Corrosion shops have 4 nos. MIG welding machine. But shop is not using MIG welding process for corrosion attention. This is being ensured. This is being ensured. This is being ensured. This is being ensured.



repairs to underframe members, the coach body should be lifted off the bogies and kept on trestles. For repairs to side wall and end wall, no lifting is required. iii) The parts of a coach requiring corrosion repairs most commonly are: 1. Head stock (refer figure 2.4) For replacement of head stock, the following parts need be stripped first: Side buffers. Plywood/compreg and PVC

flooring. end partition and electrical

wiring draw gear assembly. end portion of BP/FP in case

of air brake coaches. Before the corroded portion is cut off, the auxiliary head stock and the two sole bar ends should be firmly supported to rail lines. The corroded head-stock is then replaced as per annexure-v of RDSO Technical pamphlet no. C-7602 (Rev.1). Only 8 mm thick corrosion resistant steel sheets should be used for head stock repairs. 2. Sole bar For carrying out repairs to sole bar, it is necessary to strip first the interior fittings, laminate panelling and window frames. Before cutting off the corroded portion of sole bar, both the adjacent ends should be supported to the rail lines. The new sole bar piece should be welded from outside and inside. To facilitate welding from inside, the coach body should be lifted and kept on trestles. 2.1 Stiffening of sole bar at doorways

This is being ensured. This is being ensured.



As incidence of corrosion in sole bar is predominant in the lavatory areas and adjoining doorways, the sole bar was strengthened in all coaches manufactured since 1974 by providing a box section as shown in RDSO sketch nos. 76011 & 76012. The doorways of luggage compartments in SLRs were strengthened as shown in RDSO sketch no. 76013. These modifications should be carried out in all coaches during POH, if not already done. On coaches which have not been manufactured or so far modified in accordance with above, this can be done as shown in RDSO's sketch nos. 78102, 78103 & 78096. 2.2 Corrosion repair of sole bar Repairs to sole bar for replacement of corroded portions at the locations mentioned below should be carried out as per the respective RDSO sketches indicated: At locations other than lifting

pads and body bolster – RDSO sketch no. 76018.

At body bolster and lifting pad locations - RDSO sketch no.76019.

3. Side wall members For repairs to side and end wall sheets, the interior fittings, laminate panelling and window frames should be stripped first. Corrosion repair of side/ end wall sheets, body pillars and turn unders should be done as per RDSO sketch no. 76 020. 4. Trough floor For replacement of trough floor, first decolite/ plywood flooring needs to be stripped. Corrosion

This is being ensured. This is being ensured. This is being ensured. This is being ensured. This is being ensured.



repairs to trough floor at the locations mentioned below should be done as per the respective RDSO sketches indicated: At end lavatories of two-doors

and three-doors aside coaches - RDSO sketch no. 76021.

At end lavatories of four-doors aside coaches - RDSO sketch no.76022.

At middle lavatories of four - doors aside coaches – RDSO sketch no. 76023.

9 ROOF REPAIRS 203a Roof repairs i) In ICF coaches, roof should be checked for corrosion. Special attention should be paid at location where gutter mouldings are welded and ventilators bolted. Corroded roof should be repaired according to the instructions given in annexure VII of RDSO Technical pamphlet no. C- 7602 (Rev.1) for corrosion repairs of ICF coaches. 203b TRA type Roof Ventilators repairs i) Examine the roof ventilator for damage or corrosion or leakage. If no corrosion is observed then seal the joints and crevices with water proof sealing agent. Ventilators found beyond repairs should be replaced as per RDSO technical pamphlet No.C-7602 (rev.1) annexure-VII. The securing bolts should be replaced whenever a ventilator is removed. Otherwise, they should be checked for tightness. Loose and corroded bolts should be replaced.

203 Roof attention is not adequate. There is no system to check roof leakage through Shower test. Roof is attended on the basis of open line report for roof leakage during rainy season. Ventilators are attended on condition basis and defective ventilators are replaced.



ii) After repairs and refitting, ventilators should be tested for water leakage at their base joints at the time of roof testing. 203c Roof testing All coaches after POH repairs should be tested under water spray for roof leakage before they are finally turned out from the workshop. For this purpose, a fixture designed to simulate monsoon conditions should be provided in the workshop.

This is not being followed as shop has no facility for roof testing. Shop has no facility for roof testing in shower.

10 REPAIRS TO DOOR HANDLES Examine the door handle for breakage, damages. If the fixing bolts are loose or missing, tighten the bolts. Replace the door handles which are found beyond repairs.

204 This is being ensured.

11 REPAIRS TO DOOR PIVOTS Examine the door pivots for corrosion, breakage or wear by cutting the bottom portion of outer panel. Cut the corroded portion of the door pillar (Z molding) and weld new piece joining the door pivot pin. If the female socket is worn or damaged beyond repairs then replace it. Replace the bush provided in the socket.


12 REPAIRS TO PARTITION WALL, SEAT PILLAR / MOUNTING PLATE Examine seat pillar/mounting plate for corrosion or breakage, etc. at bottom ends. If found corroded, repair the same as per RDSO technical pamphlet no. C-7602 (Rev.1).

206 This is attended on condition basis.

13 REPAIRS TO DRAW AND BUFFING GEAR SUPPORT STRUCTURE Examine the draw gear support structure for corrosion,

207 This is attended on condition basis. However quality of cleaning to scrap



breakage, etc. If the corrosion is light, scrap off the rust to bare metal, clean well and re-paint. If the corrosion is heavy, replace the corroded angle or gusset plate with new support angle. Similarly examine the buffing gear support structure for corrosion, breakage, etc. If the corrosion is light, scrap off the rust to bare metal, clean well and re-paint. If the corrosion is heavy, replace the corroded angle or stiffeners.

off the rust to bare metal and re-paint is not adequate. For light corrosion, quality of cleaning to scrap off the rust to bare metal and re-paint is not adequate.

14 REPAIRS TO BODY BOLSTER Examine the body bolster for corrosion, breakage, wear, etc. If the corrosion is light, scrap off the rust to bare metal, clean well and re-paint. If the corrosion, breakage or wear are beyond repair, replace the body bolster. Check the area surrounding centre pivot pin mounting holes for cracks.

208 Body bolster is not replaced and repaired as approved in LTO issued by CWM/LLH.

15 REPAIRS TO CENTRE PIVOTS Clean and examine the centre pivot for bent, wear, cracks. Cracks shall be detected by doing chalk testing or magnaflux dye penetrant test. If the centre pivot is found cracked or worn beyond repair, it should be replace. Check the mounting bolts for loose or missing. Tighten and lock the bolts with locking plate.

209 Chalk testing of centre pivot is being done. Centre pivot is changed on condition basis.

16 WATER TANK SUPPORT STRUCTURE Examine the water tank support structure for corrosion, breakage, wear, etc. If the corrosion is light, scrap off the rust to bare metal, clean well and re-paint. If the corrosion, breakage are beyond repair, replace the corroded angle with new angle of suitable size as per the requirement. Replace

210 Water tank structure is attended on condition basis.



the rubber/wooden packing if perished or damaged.

17 REPAIRS TO FLOOR CHANNEL Examine the floor channel for corrosion, breakage, wear, etc. by cutting opening the PVC and plywood flooring where the corrosion suspected. If the corrosion is light, scrap off the rust to bare metal, clean well and re-paint. If the corrosion, breakage are beyond repair, replace the corroded channels with new channel of suitable size as per the requirement.

211 This is being ensured. Corroded channels are replaced with new chanels.

18 WELDING

a) Reference may be made in this connection to the approved brands of electrodes issued by RDSO. Welding electrodes and paints should be of the prescribed quality conforming to the relevant IS/IRS specification.

3.1.5 (C-7602)

For IRS M - 41 grade, recommended Electrode is RDSO class ‘D’ or AWS 8108. However, LLH shop is using RDSO class A2 electrode for corrosion attention. Shop is not using MIG welding process for corrosion attention.

b) Ensure that the welders deputed are tested and certified by Chemist & Metallurgist of the Railways.

212 Welders are deputed for training at BTC attached to shop for training. Samples are prepared as stipulated in IS 7310 Pt I, and certified by CMT/LLH. Records have been checked and few certificate checked and observed that all samples prepared for certification are not checked in accordance with IS 7310 Pt I provision.

c) Ensure that no electric welding on the coach is carried out without proper earthing.


d) The distorted and bent parts are heated and straightened.


e) Welding machines Availabity M shop Transformer type: 62 + (12 def) Inverter type: NIL MIG welding; 2 nos SCR shop Transformer type: 127



Inverter type: NIL MIG welding: 02 nos

f) Welders skills Two shop of LLH are carrying out corrosion attention and deployment of welders are as under: M shop (for heavy and medium) – total welders 122 (Grade A: 65 Gr ‘B’ 14 & Gr ‘C’- 44) SCR Shop (For light and medium): – total welders 140 (Grade A: 37, Gr B 43, Gr C 60

19 SURFACE TREATMENT AND PAINTING

a) Ensure that the system exists for proper surface treatment of the parts and the parts are applied with protective paint. Also, the thick sections such as sole bars, cross bearers etc. are grit/shot blasted and immediately given a protective coat of red oxide, zinc chromate primer paint.

212 Shop has no facility for shot / grit blasting. Shop has facility of hot phosphating.

b) All body shell replacement components less than 5mm thickness used for corrosion repairs should be hot phosphate and applied with protective paints. Cold phosphating should be done on areas where welding has been carried out on hot phosphate components.

3.1.2 (C-7602)

Shop has recently installed hot phosphate plant with pollution control equipment. Components such as trough floor, sole bar piece, turn under piece; channels, pillar bracket small etc are given hot phosphate attention. After hot phosphate, items are given anti –corrosive paint. IRS M-41 trough floor is also provided with tissue paper after hot phosphate.

c) Zinc rich primer should be used where spot welding is done

3.1.3 (C-7602)

This is being done.

e) The coach body is cleaned after repair.

1201 This is being followed.

f) If the condition of the paint so warrants or at every 5th POH of a coach, the paint should be completely removed to the bare metal and the coach repainted

1201c This is being followed.



as per paint schedule A'. If the general condition of the paint is good, follow paint schedule `C'.

g) Ensure that the painting is done as per the specified schedules.

1202 1203

This is being followed.

h) Paint the head stock and all visible members by RDSO specification No M & C /PCN/123/2006 for high performance anticorrosion epoxy coating.

This has not been implemented till date. Shop has placed indent for procurement of paint with this specification but not yet received.

20 DOCUMENTATION

After corrosion repairs are completed, particulars should be entered in the check-lists. The check lists shown on sketch no. 76032 to 76036 pertain to coaches which are on line in large number and are typical. Suitable changes in the list may be made to suit other type of coaches. A diagram of the coach in standard A-4 size should be marked suitably to indicate the parts of the shell replaced during corrosion repair with specific details of the location and extent of corrosion. The diagram and the check-list should be filed in a folder maintained for each coach.

4.0 (C-7602)

Documentation is poor. Shop is not strictly maintaining corrosion diagram. Details of corrosion attention with diagram and check list for each coach is not maintained at LLH shop.

21 SUPERCHECKING There is no system to carry out super-checking of repair by higher official. After corrosion attention, the same is checked by supervisor concerned only.

22 STATUS OF CORROSION RELATED MODIFICATIONS

a) Stiffening of sole bars at doorways:

3.2.1 (C-7602)

This has already been implemented.

b) Lifting pads 3.2.2

(C-7602)


c) Tubular frame below lavatories 3.2.3

(C-7602)


d) FRP tissue sand witched between layers of bitumen

3.2.5 (C-

IRS M-41 trough floor is given hot phosphate treatment and tissue



7602) sand witched provided between layers of bitumen.

e)

Trough floor: 13 mm diameter holes provided in the event of trough floor for drainage of condensation were increased to 19mm so as to allow quicker drainage in coaches.

3.2.6 (C-7602)

Already implememnted. Provision of enlarged holes (19mm) on SS trough floor for drainage of water is being done in all new fitment of trough floor

f)

Stainless steel trough floor 3.2.7 (C-7602)

Shop has MC of both SS trough floor & IRS M-41 trough floor. SS trough floor: MC – 4 coach sets (100 pc) IRS M-41 trough floor: MC – 8 caoch sets (200 nos)

g)

Body side doors Completely open bottom and a removable inside panel to facilitate inspection of the outside panel.

3.2.10 (C-7602)


h) Skirting plates for vacuum reservoir and battery boxes

3.2.11 (C-7602)

NR. Coach converted to air brake system

i) Lavatory pan with longer neck 3.2.12

(C-7602)


j) Lavatory flooring 3.2.13

(C-7602)

Compreque sheet flooring + PVC in AC coaches

k)

Stainless steel inlay in lavatory instead of decolite flooring: In order to eliminate any leakage of water or chloride through the floor leading to corrosion of the underframe, ICF has started providing a stainless steel inlay in the lavatory with conventional lavatory pan duly supported as per Drg.No.ICF/SK-1-0-666 Alt.’d’.

3.2.14 (C-7602)

Shop is providing SS inlays with PVC flooring in coaches only against RSP provsion and status for provsion of SS inlays during last three years is as under: – 2008 – 09: 02 nos 2009 – 10: 14 nos 2010 – 11: 19 nos.

l)

Flooring in pantry cars 3.2.18 (C-7602)

Flooring consisting of PVC sheet over compreque sheet with Aluminum chequred sheet on top all over the coach except lavtory has been followed. Renewal in done on condition basis.



m)

PVC flooring over ply wood 3.2.19 (C-7602)

PVC flloring over compreque sheet is being done. Status of PVC flooring is as under: 2008 -09: 2490 coaches 2009 -10: 2309 coaches 2010 – 11: 1836 coaches

n)

Battery box frames: To prevent corrosion battery box frames are now being hot galvanised. The battery boxes should be fitted with FRP trays to ICF drg. No.GS-7-1-018 during POH

3.2.21 (C-7602)

Hot galvanizing is not being done. FRP trays are fitted

Annexure Corrosion attention of coaches during last six months

Month Total

outturn

Heavy corrosion Med corrosion Light and light medium

corrosion NAC AC NAC AC

Jul’10 210 14 - 23 1 172

Aug’10 220 17 - 20 1 182

Sep’10 193 8 - 24 3 158

Oct’10 184 12 - 21 3 148

Nov’10 208 10 - 30 3 166

Dec’10 215 21 - 28 3 163

quality audit [02-2011] corrosion repair of coaching stock at llh on 18.01.11

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