MAINTENANCE FACILITIES

Q Which factors are considered for deciding about the creation of a new Diesel
Shed? How would you select the site for construction of a Diesel Shed?
Requirement of a new diesel shed should be based on the following points

Working out total requirement of locomotives. Requirement of locomotives is worked

out on taking into consideration the future growth of passenger and freight traffic
and length of addition section / track being added on the Railway. Power plan for
each division is made considering the future traffic growth for next six months and
can be helpful in calculating the loco requirement. As a thumb rule, one loco is
required for every 5 Km on single line and foe every 3 Km on a double line.
Calculate total loco holding as well as loco holding capacity of various diesel sheds
of the Railway.
Compare total loco requirement with loco holding as well loco holding capacity and
calculate the net deficiency or surplus. Global view should be taken for this
comparison.
If the total loco requirement is more than the loco holding of a particular railway,
then first check the holding capacity and whether there is a scope for homing
additional locos or not. If spare holding capacity is sufficient, there is no need for a
new diesel shed. But if the spare holding capacity is not commensurate with the
additional loco requirement and the berthing capacity of existing diesel sheds can
be increased, then sheds should be expanded to take care of additional requirement.
However in absence of any scope for further expansion of sheds, construction a new
diesel shed can be though of.
While deciding about the diesel shed, distance of the nearest existing diesel shed
from the farthest point should also be taken into consideration.
Electrification of the route in near future is also an important factor for deciding
about the construction of a new diesel shed.

Once it is decided to set up a new diesel shed, following factors to be considered for the
selection of the site

Availability of land and its cost.

Transport facilities, accessibility through road, rail and other modes.
Availability of power and its cost.
Communication facilities and its linkage with other cities.
Educational facilities Adequate schools, Medium of instruction, Quality of
education, etc.
Housing facilities.
Ancillary units and industrial development.
Human Resources Availability of local staff, willing trained staff to be posted there,
etc.
Distance from farthest point of the section, where locos are to be provided. Will it be
easier to pay attention to the isolated sections?
Vicinity to other diesel sheds.
Ease of maintenance Weather / climatic conditions, distance from main city, etc.
External threats Flood prone areas, seismic zone, terrorist threats, general law
and order situation, etc.

Other related activities based at the proposed place like coaching / freight
maintenance depot, crew changing point, terminal section, yard operation, relief
equipments, etc.
Scope for any future expansion.

Q What are the various factors considered while deciding the lay out of a diesel
shed homing 100 diesel locos? What point should be considered while
constructing the shed? Explain with a sketch various service facilities
provided in diesel shed. What are various M&P items required in the shed?
Following factors may be considered while finalizing the shed lay out

A unidirectional movement of locomotive in the shed is preferable.

Separate entrance and exit points should be provided to a avoid bottlenecks.
The layout should permit a locomotive to skip stage of servicing without hampering
the flow of other locomotives.
The shed should have covered accommodation in its repair area for about 25-30% of
the fleet homed. The yard of the maintenance shed should be able to hold at a time
about 50% of the total holding of the shed.
Each line in the covered repair area of the shed should be able to hold 3
locomotives. The lay out should provide for possibility of expansion width-wise i.e.
by providing more lines side by side. Expansion along the length of the running
lines should not be adopted.
The work area in the shed should be divided into two distinct portions, one dealing
with servicing and light maintenance and the other with heavy repairs. Facilities
should be provided in the same sequence in which an incoming locomotive is to be
attended to.

Following points should be considered while constructing a shed

A 3-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 out side
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 point level between the rails is kept still lower to
enable proper examination of under-gearing. Above the depressed floor level, a
platform level is provided, which is at the same height as the locomotive floor. To
attend to all the components of the locomotives 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.
Flooring should be easily washable so that split oil can be effectively removed. All
flooring should be finished with a hard top to withstand abrasion resulting from
handling of heavy parts and movement of material trollies etc. Wooden flooring is
not recommended. Concrete flooring is acceptable.
Flooring is the heavy lifting bays of the shed should be adequately strengthened.
Special reinforcement is required in the location where heavy duty high lift jacks are
installed.
To minimise cracking and to facilitate repairs flooring should be divided into
rectangular panels, with sides not exceeding 2 meters, using dividing strips.

The platform and ramps as also steps should be protected with steel or cost iron
edging of non-skidding type.
Pits should have convex flooring and efficient drainage. Stilt arrangement consisting
of steel beam on stub columns should be flowed, so far as possible for supporting
track in the pits, since it permits better lighting and ventilation of pits.
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.
The minimise the dust nuisance in working areas, a length of approximately 30
meters beyond the cover area should be paved.
A uniform roof height should be preferably adopted for all bays to enable convenient
construction and dispersion natural light. The minimum height is governed by the
requirement of heavy lifting bay.
The roof should be of a construction that caters for maximum natural light in
working area. Translucent corrugated sheets suitably arranged in pepper-pot
form.
Roof extractors and exhaust fans should be provided at suitable locations to remove
smoke and fumes.
Fabrication of roof structure by welding is preferable in order to conserve steel.
The repair area in the shed should be made as dust proof as possible. All large
should be provided with rolling or other type of shutters.
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 alteration are required to be
structure and the foundation.
To protect personnel working on the elevated platform from falling down, when the
line is not occupied by a locomotive, chain guards should be provided. These be
fixed in such a manner near the edge of the platform that they can be removed
easily when a locomotive is placed alongside.

Servicing facilities
Following service facilities should be provided in a diesel shed for smooth and
efficient functioning
1)

2)
3)
4)

5)

Washing and cleaning 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
locomotives. Manual washing with brushes (fitted with long handle) IS
RECOMMENDED FOR SMALL SHED. Automatic washers, with mechanised sprays,
brushes etc. can be justified only for very big running sheds with large number of
locomotives. 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.
Fuel supply installation For fuelling the locomotives.
Lubricating oil storage and dispensing system.
Cooling water treatment and dispensing Diesel engine water should be treated
in accordance with maintenance instructions laid down for different classes of
locomotives. The most widely used treatment is that with chromate.
Repair Area The repair are of the shed is generally divided into two parts (i)
Light repair bay (ii) Heavy repair bay including overhauling sections for various subassemblies.

All the major schedules upto half yearly are carried out in light repair bay. This
area is further divided into two parts Mail loco repair bay and goods section
including Quarterly and HY schedule.
In the sub-assembly overhauling area, separate areas should be demarcated for
specialised repair groups such as
Diesel Engine
Electric rotating machine
Cyl. Head, piston, connecting rod, etc.
Turbo
Expressor
Governor
Fuel injection room
Cooling equipment and radiator
Brake equipment and valves
Pump, shafts, gears etc
Speedometer, gauges etc
Under-gearing components
Electrical test room including Excitation cards, BKT, reversor, etc.
Filter cleaning
Small motors
Dynamic balancing
Air Brake
Gasket Room
Millright section
Fitter benches should be suitably provided in each of the demarcated areas.
For ease of handling during repairs, suitable hoists and chain pulley blocks etc.
should be provided.
Special stands and carriers etc. for different components should be provided in
the different repair areas. For example connecting rod and piston assemblies
removal from the engine should be stacked on a rack with the connecting rods
suspended from the gudgeon pins. Special holding trays etc. should similarly be
provided for bearing shells, fuel injection nozzle etc.
6) Shed building The shed building, besides providing for the repair area, machine
shop etc., should accommodate the following

Battery charging and storage room preferably at one end of the shed building,
where fumes and gases can be easily exhausted to the atmosphere.
Instrument repair and testing room
Fuel injection repair and testing room
Engine governor repair and testing room
Brake testing room
Flaw detector room (Magnetic and Zyglo etc)
Filter storage
Tool room
Lockers and washing room
Laboratory
Drivers lobby and lockers
Booking office
Supervisors office room
Shed officers room
Office room and record room
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 Library
Lecture and meeting room
Fire fighting equipments
RPF post
Load box room
Pit wheel area.
7) Shed stores
The shed stores should have approach by both rail as well as road. The
approaches should not interfere with other movements in the maintenance shed.
Proper bins and racks should be provided for storage and handling of
components, to avoid damage during handling and in storage.
Adequate lifting facilities should be provided for handling heavy components.
Use of forks lift trucks for this purpose is preferable.
Special provision should be made for storage of rubber components since these
are subject to deformation if not properly stacked and to ageing in the presence
of air and due to effect of temperature.
While designing store building, due regard should be paid to the fire fighting
precautions.
To reduce material handling to a minimum and same time, small components
frequently required should be stocked at platform level near work areas. Heavier
components such as brake-shoes etc. can be conveniently stored at the
depressed floor level.
8) Lifting and material handling facilities
Overhead cranes of suitable capacity should be provided to serve heavy repairs
area, free floor space, a part of the machine shop and stores. Crane capacity
should be sufficient to lift the heaviest single repair able component or assembly.
Heavy duty high lift electrically operated jacks may be provided at suitable
location in the heavy repair area for lifting the locomotive. It should be possible
to alter spacing of the jacks to suit locomotives having different spacing of lifting
pads.
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.
Hand carts and trolleys should be used for movements of components. Fork lift
truck should also be provided in large maintenance sheds.
9) Illumination
Good illumination is necessary for efficient repair work. In the repair area
fluorescent light or mercury vapour lamps giving an even illumination of atleast
200 lux at platform and floor levels should be provided.
Pits should be provided with bulk head fittings for direct lighting of the undergear of the locomotive. Here also minimum illumination level of 200 lux is
necessary.
Low voltage plug points should be provided at all work areas, including the
pits, for use of portable hand lamps with flexible leads. Moveable trolleys with
provision of swivelling light can be an alternative to fixed pit lights.
10) Auxiliary Building
A small shed should be provided in the vicinity of the main shed building for
stabilising spare wheels and bogies. A 3-tonne gantry should serve the stabling
line and the next to it for proper loading and un-loading of the wheels.

 Under-floor type of wheel lathe should be provided in a large maintenance shed

for in-situ re-profiling of worn locomotives wheels. A separate shed for the
under-floor wheel lathe is preferable.
A load-box for testing a locomotive under power should be provided in every
home shed. This applies to shed handling only diesel-electric locomotives.
11) Compressed Air Air compressor should be installed in a place where minimum
disturbance due to vibrations and noise is caused to the surrounding. A separate
compressor room is recommended out side the main shed building. Compressed air
pipe lines should be laid so as to reach all working areas and adequate number of
points should be provided to tap the air supply. The layout should permit provision
of additional tapping points at a later date near locations such as machine shop,
fitter repair benches, blacksmith shop etc.
12) Laboratories In every diesel locomotives maintenance shed, it is essential to have
a well equipped laboratory to exercise control on lubricating oil, fuel oil and cooling
water. The laboratory is also helpful in carrying out metallurgical and chemical
inspection of parts and supplies received in the shed. Following major equipments
are necessary in the laboratory
Spectrograph for lube oil testing
Magnaflux testing machine
Rubber tensile testing machine
Zyglo testing machine
Oscilloscope
Ultra sonic testing machine
13)Cleaning and washing Keeping the equipment clean goes a long way in ensuring
trouble free operation and long equipment life. Suitable cleaning and washing
facilities are, therefore, absolutely necessary in every shed.
Cleaning of components immediately after their disassembly is necessary, before
any inspection or repair can be undertaken. Degreasing and cleaning facilities
whether of the vapour type or hot bath or spray-jet type are required in every shed.
Wherever justified mechanised cleaning equipment should be provided.
Special cleaning plants are required for turbocharger, after coolers, oil heat
exchangers, radiators, piston assembly, carbody filters, etc.
14) Shed offices

Offices for supervisors should be located near their place of work. This
ensure effective and constant supervision of the repair work.

The drivers booking office and lobby should be located near the point where
the locomotives are inspection and prepared for despatch.

The General Administration and other office should provide for meeting room.
15) Plant and equipment A list of machinery and plant required in maintenance sheds
of different sizes is given below

EOT Cranes 40 tons & 10 tons.

Whiting jacks 1 set of 5 jacks.

Tram beam 3 ton cranes 6

Pillar cranes with 1.5/1 to hoists 16

Forklift truck (2 T) 2

Platform truck (2 T) 5

Pick up van 2

Truck 3 Tons 1

Monorail with hoist for battery room, heavy switch gear and piston assembly.

Hoist (100 Kg) for governor, heavy switch gear.

Under floor wheel lathe

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Lathes 5

Shaping machine and drilling machine

Valve seat grinding and tool grinders

Lap master

Testing and calibrating equipments fro various sub-assemblies

Carbody filter plant

Welding plants

Cordless drills, grinders, etc

Dynamic balancing machine

Spray painting equipment

Hydraulic jacks 4

Water and grid load box.

Every shed should be provided with equipment required for testing and calibrating
various tools, machines and fixture used in repair work.
16) Fire fighting Adequate safety measures must be adopted against fire hazards in the
shed. Since large volumes of petroleum products are handled, special precautions
are necessary. Fire fighting equipment such as hydrants, hoses, extinguishers and
fire alarm boxes etc. should be conspicuously visible both at day and at night.
17) Training school For proper maintenance of the sophisticated equipment on diesel
locomotives, the work force has to be adequately trained. Each large shed should,
therefore, include a training school for imparting theoretical and practical training
to various categories of staff. Provision of a hostel attached to the training school is
necessary. The training school should be provided with a library with sufficient
books and technical literature and audio visual aid for training. Model room in the
training school should display cut-way models and working models of as many
components as possible.
18) Staff Amenities
Toilet and washing facilities and water coolers should be available both inside
the shed building and for the use of office staff.
Adequate precautions are necessary against dermatitis amongst workers
handling fuel oil, lubricants, chromates etc. Suitable cleaning agents and ample
washing facilities in the vicinity of areas where these products are handled are
necessary. Use of hand protection cream before staring work and non-irritant
cleaning soaps after completion of work should be enforced.
Staff lockers rooms, cycle and scooter stand, canteen and other essential
amenities should be provided in the shed.
Wash and change rooms.
19) Environment friendly equipment
Incinerators to dispose off waste material.
Effluent treatment pants It has become a necessity to curtail pollutants and
is a pre-requisite for getting ISO-14000.

Effluent treatment plant

Incinerator
Cleaning Plant

Water Load Box

Battery Charging

Fuel
Installation
Bahr Line
Light Repair Bay-Goods
Washing
Plant

Light Repair Bay-Mail

Heavy Repair Bay

Grid Load
Box

Over Hauling Sections

Main Store

Dematerialized
Water Plant

Office Block

Canteen

Pit wheel
Lath

Laboratory

Time Office

RPF Post

Vehicle Section

SHED LAYOUT

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