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INDIAN RAILWAYS MAINTENANCE MANUAL FOR DIESEL LOCOMOTIVES - PART 15

Document No:

Chapter –3 Infra. Facilities of Diesel Loco Shed

Version No: 1.0-d0

Date Issued: dd/mm/yyyy

Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES

Revised 2013

Printed: 2015/03/08

Page 52 of 303

3.2.15

A turn table needs to be installed as in coming years speed of mail/express trains is
bound to increase for which there will be requirement of running of locos with short
hood leading. Other-wise also, for running of mail/express trains, it is desirable to
run the trains with short hood leading. Apart from this when making Multiple Units,
turn table will be useful in ensuring that they are made with Short Hood leading on
both the sides.

3.2.16

With holding of upto 250 locos, movement of locos to and from shed will increase.
Hence, the shed should have two entry and two exit lines on each end for
unidirectional movement of locos and facility for entry/exit from both the sides to
avoid congestion.

3.2.17

With stricter environmental regulations, there is a need that the Diesel Sheds should
take energy conservation measures to reduce the carbon foot print. When
augmenting infrastructure on large scale, principles of sustainable development
need to be kept in view, which will give good returns in the long run.

3.2.18

There should be a two pronged approach for energy conservation – one to reduce
the power consumption and other to utilize otherwise wasted power for generating
power and shed building should be green building.

3.2.19

The New shed should have environmental conservation measures like Solar
distillation plant for batteries, Rain Water harvesting, ETP etc. Apart from this
Waste Heat Recovery system (from incinerator) is also a good add-on. Solar
paneling of administrative block – solar lighting, and use of Green house principles
in construction of new sheds – so that there will be good air circulation as well as
good natural lighting will be available.

3.2.20

The shed should have at least 30% Green cover.

3.2.21

Wherever there is potential, wind power can be harnessed to generate power. Indian
Railways is already planning Wind Power Plants at some places.

3.2.22

There should be a dedicated over head water storage tank to hold a supply for at
least 15 days, depending upon the availability of water supply situation in the area.

3.2.23

The drainage of shed should be well planned, which should have proper sloping,
screens, pits. If required intermediate sludge pumps may be provided where sloping
is a constraint

3.3

Sequence of Repair Operations:

3.3.1

The recommended sequence of operations for servicing is:

3.3.1.1 Cleaning and washing of under-gearing and body

3.3.1.2 Sanding

3.3.1.3 Fuelling

3.3.1.4 Inspection and topping of lube oil and cooling water

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Document No:

Chapter –3 Infra. Facilities of Diesel Loco Shed

Version No: 1.0-d0

Date Issued: dd/mm/yyyy

Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES

Revised 2013

Printed: 2015/03/08

Page 53 of 303

3.3.1.5 Repairs

3.3.1.6 Departure

3.3.2

Lines earmarked for normal servicing attention should be through lines so that
minimum time is taken in movement of loco. In the repair areas, separate lines
should be earmarked for schedule repairs and for locos needing out-of course
repairs.

3.4

Servicing Facilities:

3.4.1

Washing and cleaning:

3.4.1.1 A separate Washing installation should be provided for loco cleaning before

entering maintenance areas.

3.4.1.2 A washing apron and pit laid with concrete and provided with good drainage,

suitable hydrant points and adequate supply of water, should be located well
away from the shed building to clean the under gearing and body of the locos.

3.4.1.3 Automatic washers with mechanized sprays, brushes etc. should be installed to

improve the quality of cleaning and minimize manual labour content.

3.4.1.4 Hose and nozzle arrangement for spraying the under-gearing with water under,

pressure will ensure proper removal of grease and oil from the chassis.
Provision of a boiler to give a steam jet will be an additional help.

3.4.1.5 Annexure 3.2 shows schematically a washing installation.

3.4.2

Sanding:

3.4.2.1 Sand should be stored under cover to keep it dry. Sand drying arrangements

may be necessary in areas having heavy rainfall.

3.4.2.2 Sand should be properly sieved before being filled to prevent the sanding

apparatus on the locos getting chocked.

3.4.2.3 Mechanized sanding facilities should be installed to minimize manual labour

content and avoid unnecessary spillage of sand.

3.4.2.4 Sanding point should be at an adequate distance away from the fuelling

installation and the running shed building.

3.4.3

Fuel supply installation: This has been dealt with in Chapter 8 (a).

3.4.4

Lubricating oil storage and dispensing: This has been dealt with in Chapter 8 (b).

3.4.5

Cooling water treatment and dispensing: Diesel engine water should be treated
in accordance with maintenance instructions laid down for different classes of locos
as per RDSO MI 15.

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Document No:

Chapter –3 Infra. Facilities of Diesel Loco Shed

Version No: 1.0-d0

Date Issued: dd/mm/yyyy

Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES

Revised 2013

Printed: 2015/03/08

Page 54 of 303

3.5

Shed Construction:

3.5.1

Three- level working floor arrangement should be provided. The rail level in the
repair area is the same as the general shed floor level. The depressed floor area
outside the rails is kept lower than the shed floor level so as to be able to attend
effectively to the bogies and under- gear. The pit level between the rails is kept still
lower to enable proper examination of under gearing. Above the depressed floor
level, platform level is provided, which is at the same height as the loco floor, to
attend to all components of the loco above the under frame. Ramps or steps should
be provided to conveniently connect the three working levels with the general floor
level in the shed. A typical cross section of the three level arrangements is shown in
the sample drawing of a typical shed enclosed as Annexure 3.3.

3.5.2

Flooring should be easily washable so that spilled oil can be effectively removed.
All flooring should be finished with a hard top to withstand abrasion resulting from
handling heavy parts and movement of material trollies, etc. Hardonite flooring is
acceptable on the ground level in the Running Repair Bay and anti skid steel tiles
flooring in Heavy Repair Bay. Epoxy flooring should be used in the Equipment
Repair Bay and over Catwalk surfaces of the Running Repair Bay. Annexure 3.4
shows Hardonite flooring details and Epoxy flooring.

3.5.3

Flooring in the heavy lifting bays of shed should be adequately strengthened.
Special reinforcement is required in the location where heavy duty high lift jacks
are installed.

3.5.4

To minimize dust nuisance in working area, RCC paved area for at least in 30 meter
distance on both sides of shed bays (front and back) should be provided. Also, other
paved area, wherever provided, should be RCC.

3.5.5

Roads in shed should be of RCC.

3.5.6

To minimize cracking and to facilitate repairs, flooring should be divided into
rectangular panels, with sides not exceeding 2 meters using dividing strips.

3.5.7

The platforms, and ramps as also steps should be protected with steel or cast iron
edging of non-skidding type.

3.5.8

Pits should have convex flooring and efficient drainage. Stilt arrangement
consisting of steel beam on stub columns should be followed, as far as possible, for
supporting track in the pits, since it permits better lighting and ventilation of the
pits. See Annexure 3.4A.

3.5.9

The edge of the elevated platform should be suitably raised to provide a rim to
prevent tools and materials from rolling off. This also reduces the possibility of men
slipping at the edge.

3.5.10 To protect personnel working on the elevated platform from falling down when the

line is not occupied by a loco, chain guards should be provided. These should be
fixed in such a manner near the edge of the platform that they can be removed
easily when a loco is placed alongside. Provision of sockets in the platform floor in
which steel pipes can be inserted is a convenient method of doing so.

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Document No:

Chapter –3 Infra. Facilities of Diesel Loco Shed

Version No: 1.0-d0

Date Issued: dd/mm/yyyy

Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES

Revised 2013

Printed: 2015/03/08

Page 55 of 303

3.5.11 A uniform roof height should be preferably adopted for all bays to enable

convenient construction and dispersion of natural light. The minimum height is
governed by the requirement of heavy lifting bay.

3.5.12 The roof should be of a construction that caters for maximum natural light in

working area. 25% translucent corrugated poly carbonate sheets suitably arranged
in a row form (Annexure 3.5) is recommended, in preference to north- light
glazing.

3.5.13 Now-a-days, still better design of roof which uses minimum height with less

clogging by cross members, affording uninterrupted ingress of natural light and an
aesthetic view are available, which should be adopted. A typical Rafter roof is
shown in Annexure 3.6. and Annexure 3.7

3.5.14 Rotary turbo ventilators should be provided at suitable locations and in sufficient

numbers to remove smoke and fumes (a typical arrangement shown in Annexure
3.8).

3.5.15 The repair area in the shed should be made as dust proof as far as possible. All large

openings should be provided with rolling or other type of shutters.

3.5.16 Suitable provision should be made while laying out end columns of bays which

may require to be extended at a later date, so that minimum alterations are required
to the structure and the foundations.

3.5.17 Sufficient welding points should be provided in shed @14m distance in all the

repair bays

3.6

Lifting and Material Handling Facilities

3.6.1

Overhead cranes of suitable capacity should be provided to serve repair areas, a part
of the machine shop and stores.

3.6.2

Crane capacity should be sufficient to lift the heaviest single repairable component
or assembly. Overhead crane is not intended to lift complete loco singly; however,
it should be capable of lifting a complete loco from one end so as to enable a bogie
to be run out from under it.

3.6.3

Heavy duty high lift electrically operated jacks may be provided at suitable
locations in the heavy repair area for lifting the loco. It should be possible to alter
spacing of the jacks to suit locos having different spacing of lifting pads.

3.6.4

Tram beam cranes operated from the floor level and hoists should be provided at all
suitable work locations. Wherever it is possible to provide these facilities and
dispense with overhead cranes, the shed structure can be made lighter.

3.6.5

Fork lift/Platform trucks should be provided in maintenance sheds for movement of
components and assemblies.

3.6.6

Movement of material flow should be made smooth. Material flow can be traced
onto a plant layout through spaghetti diagram.

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