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Guidelines for IRSMEProbationers, IRIMEE/ JMP

GUI DEL I NES FOR I RSM E


PROBATI ONERS
VOL I & VOL II

INDIAN RAILWAYS
INSTITUTE OF MECHANICAL & ELECTRICAL ENGINEERING
JAMALPUR - 811214

Guidelines for IRSMEProbationers, IRIMEE/ JMP

WELCOME
I extend a hearty welcome to you on your joining the Indian Railways as an officer
of the Indian Railway Service of Mechanical Engineers (IRSME). You can be
justifiably proud and happy to be a member of the IRSME. Which has a more than
75 years tradition of dedicated service and is known for managerial excellence.
Out of the total three years PROBATION PERIOD, you will be spending the next
one and half years of probationary period in getting to learn about Railways,
particularly the working of various units of the Mechanical Department here at
IRIMEEand at various Production Units, Zonal Railways, Workshop, Sheds, depots
and RDSO etc. These guidelines have been prepared with a view to help you
learn about the Railway Organization, goals of the Mechanical Department, your
training schedule, broadly what you are expected to learn at various units and
about IRIMEE. Please go through this book and keep it with you for reference
during your training period.
We hope and expect that you will make best use of this one and half year period
by taking initiatives and cultivating enthusiasm for learning as much as possible.
If your need any help or have nay doubts/ clarification to seek, please do feel
to get in touch with IRIMEE/ Faculty or the concerned officers at your place of
training. I am sure they will be very happy to give the required help and guidance.

Director, IRIMEE

Guidelines for IRSMEProbationers, IRIMEE/ JMP

ENGINEERING: AN IDEALCAREER

Engineering is a great profession. There is the fascination of watching a figment


of the imagination, emerge through the aid of science to plan on paper. Then it
moves to realization in stone or metal or energy. Then it brings jobs and homes
to men and women. Then it elevates the standard of living and adds to the
comforts of life. This is the engineers high privilege.
The great liability of the engineer compared to men of other professions is that
his works are out in the open where all can see them. His acts, step by step, are
in hard substance. He cannot bury his mistakes in the grave like the doctors.
He cannot argue them in to thin air, or blame the judges like the lawyers. He
cannot, like politicians, screen his shortcomings by blaming his opponents and
hope the people will forget. The engineer simply cannot deny he did it. If his
works do not work, he is damned. On the other hand, unlike the doctor, he is
not a life amongst the weak. Unlike the soldier, destruction is not his purpose.
Unlike the lawyer, quarrels are not his daily bread. To the engineer falls the job
of clothing the bare bones of science with life, comforts and hope. No doubt, as
years go by, people forget which engineer did it, even if they ever knew. Or some
politician puts his name on it. Or they credit it to some promoter who used other
peoples money. But an engineer himself looks back at the endless stream of
goodness that flows from his success with satisfactions that few other professions
may know. And the verdict of his fellow professionals in the entire accolade he
wants.

Herbert Hoover
(President of USA)

Guidelines for IRSMEProbationers, IRIMEE/ JMP

Guidelines for IRSMEProbationers, IRIMEE/ JMP

INDEX:
Volume I (General)
SN

Item

Page no

1.
2.
3.
4.
5.
6.
7.

A. ABOUT INDIAN RAILWAY


Evolution
vision
Statistical Summary
Railway Organization
Vision 2020 - Goals at a Glance
Vision 2020 - Critical Mission Area
Vision 2020 - Operational Strategy

1
1
2
5
8
10
16

1.
2.
3.

B. ABOUT MECHANICAL DEPARTMENT


Organization at zonal HQ
Divisional Office
Workshops

24
24
24

1.
2.
3.
4.

C. ABOUT IRIMEE
History
Training activities at IRIMEE
Computer Centre
Library

25
25
26
27

1.
2.
3.
4.

D. IRSME PROBATIONERS TRAINING


Distribution of 78 weeks Training Schedule
Training Procedure Important Points to note
Railway Board Policy Circular letter for training
Max. Marks Distribution during Probation

28
29
31
37

1.
2.
3.
4.
5.
6.

E. ITEMS OF GENERAL INTEREST


Territorial Army
Hostel
Recreation facilities
Address of Important Rest House of I.R.
List of ORH at placed of Tourist Interest
Faculty List & Phone Nos

38
38
38
39
40
42

F. IMPORTANT NOTEs
1.
Regarding Uniform

43

Guidelines for IRSMEProbationers, IRIMEE/ JMP

GUI DEL I NES FOR I RSM E PROBATI ONERS

VOL I (General)

Guidelines for IRSMEProbationers, IRIMEE/ JMP

A. ABOUT INDIAN RAILWAYS


1. EVOLUTION: (Source: http:/ / www.indianrailways.gov.in)
The first railway on Indian sub-continent ran over a stretch of 21 miles from Bombay to Thane. The idea
of a railway to connect Bombay with Thane, Kalyan and with the Thal and Bhore Ghats inclines first
occurred to Mr. George Clark, the Chief Engineer of the Bombay Government, during a visit to Bhandup
in 1843.
The formal inauguration ceremony was performed on 16th April 1853, when 14 railway carriages
carrying about 400 guests left Bori Bunder at 3.30 pm "amidst the loud applause of a vast multitude
and to the salute of 21 guns." The first passenger train steamed out of Howrah station destined for
Hooghly, a distance of 24 miles, on 15th August, 1854. Thus the first section of the East Indian Railway
was opened to public traffic, inaugurating the beginning of railway transport on the Eastern side of the
sub-continent.
In south the first line was opened on Ist July, 1856 by the Madras Railway Company. It ran between
Veyasarpandy and Walajah Road (Arcot), a distance of 63 miles. In the North a length of 119 miles of line
was laid from Allahabad to Kanpur on 3rd March 1859. The first section from Hathras Road to Mathura
Cantonment was opened to traffic on 19th October, 1875.
These were the small beginnings which is due course developed into a network of railway lines all
over the country. By 1880 the Indian Railway system had a route mileage of about 9000 miles. INDIAN
RAILWAYS, the premier transport organization of the country is the largest rail network in Asia and the
world's second largest under one management.
Indian Railways is a multi-gauge, multi-traction system detail of which is given in subsequent
paragraphs.

2. VISION STATEMENT (Source: Indian Railways: VISION 2020)


Indian Railways shall provide efficient, affordable, customer focused and environmentally
sustainable integrated transportation solutions. It shall be vehicle of inclusive growth, connecting
regions, communities, ports and center of Industries, commerce, tourism and pilgrimage across
the country. The reach and access of its service will be continuously expanded and improved its
integrated team of committed, empowered and satisfied employees and by use of cutting edge
technology.

3. RAILWAYNETWORK (Source: Indian Railways: Year Book 2009-2010 As on 31.03.2010)


Gauge

Route KM

Running Track Km

Total Track Km

BG

54,257

76,758

1,01,486

MG

7,180

7,792

9,290

NG

2,537

2,537

2,537

Guidelines for IRSMEProbationers, IRIMEE/ JMP

4. RAILWAYORGANISATION
4.1 In the Foundation Course at Railway Staff College Vadodara and during the course of your training,
you will learn about the organization and the functioning of the Railways. However, a brief
introduction to this is being given here.
4.2The apex body of the Indian Railways is the Railway Board. The Board is responsible for the
administration and the overall management in the Railways. The Board also discharges the
functions of the Ministry of Railways under the control of Minister of Railways. The members of the
Railway Board are Chairman (CRB), the Financial Commissioner (FC) and five functional members
one each for Mechanical Engineering (MM), Civil Engineering (ME), Electrical Engineering (EL), Staff
(MS) and Transportation (MT). The CRB is ex-officio principal Secretary to the Government of India
while the FC and the other members as ex-officio Secretaries. The Members of the Railway Board
are assisted by Additional Members and Executive Directors who head functional Directorates.

Guidelines for IRSMEProbationers, IRIMEE/ JMP

4.3 For effective day to day management, the Railways have been divided into 16 Zonal Railways,
each under the control of General Manager. The Zonal Railways with their headquarters are listed
below:S.N.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17

Railway
Central
Eastern
Northern
North Eastern
Northeast Frontier
Southern
South Central
South Eastern
Western
East-Coast
North Central
East Central
North-Western
South-Western
West Central
South East Central
Kolkata Metro Railway

Headquarters
Mumbai CST
Fairlie Place, Kolkata
New Delhi
Gorakhpur
Maligaon, Guwahatri
Chennai
Secunderabad
Garden Reach, Kolkata
Church Gate, Mumbai
Bhubaneshwar
Allahabad
Hajipur
Jaipur
Hubli
Jabalpaur
Bilaspur
Kolkata

4.4 On each Zonal Railway, the General Manager (GM) functions through Heads of Departments (HODS)
who control the various functions of departments. The Mechanical Engineering department is
under the control of the Chief Mechanical Engineer (CME). . Each Department is headed by a
principal Head Department (PHOD) who is assisted by other HODs who control specific functions.
The PHODs are in the higher Administrative Grade (HAG) same as AGMs grade while other HODs
are in SAG. This may vary slightly from Railway to Railway.
4.5 The Zonal Railways are further sub-divided in to smaller operational units called Divisions, which
are responsible for the actual running of trains. Divisions are headed by a Divisional Railway
Manager (DRM) who is turn is assisted by Branch Officers of various branches (departments). In the
Mechanical Engineering Department, there are normally three divisional branch officers, viz. Senior
Divisional Mechanical Engineers (Sr.DMEs) respectively for power (Loco Operations), Diesel and
Carriage & Wagon. The Sr.DME(Power) is responsible for the operation of locomotives on divisions
as well as the control of diesel loco crew. Sr.DME (Diesel) in-charge of Diesel Locomotive Sheds is
responsible for the maintenance of diesel Loco. Sr.DME (C&W) is responsible for the maintenance
of coaches and wagons. Most Divisional Officers are in the Junior Administrative Grade and are
designated as Senior DMEs. Similarly, there are other Brach officers in each division on the same
analogy as the Zonal Railway Headquarters.

Guidelines for IRSMEProbationers, IRIMEE/ JMP


4.6 You will thus find that at both the Zonal Railway and the divisional levels, there are several officers
of equal status belonging to different disciplines working as a team. It is best that you appreciate
this and develop a good team spirit for the success opf the organization and your own success.
4.7 Back up workshop support is provided to the operational divisions by workshops that are not part
of the divisions. Each such workshop is usually headed by a Chief Works Manager (XCWM), who
reports to the CME, either directly or through a Chief Workshop Engineer.
4.8The Indian Railways have six Production Units, direct from the repair and overhaul workshops
discussed above. The production units are:SN Unit
Location
Product
1.
DLW-Diesel Locomotive Works
Varanasi
Diesel Loco
2.
DMW-Diesel Modemission Works
Patiala
Diesel Loco Components
3.
ICF-Integral Coach Factory
Chennai
Coaches, DEMUs & EMUs
4.
RCF-Rail Coach Factory
Kapurtala
Coaches
5.
Rail Wheel Factory
Bangalore
Wheels & Axles
6.
CLW-Chittaranjan
Locomotive Chittaranjan Electric and other Locomotives
Works
In addition to above the production units which are in pipe line are:
SN
1.
2.
3.
4.

Unit
Cast Wheel Plant
Diesel Loco Factory
Electric Loco Factory
Rail Coach Factory

Location
Bela, Bihar
Marhaura, Bihar
Madhepura, Bihar
Raebareli, U.P

Product
Wheel
Diesel Loco
Electric Loco
Coach

4.9 The Railways have an R&D Organisation at Lucknow. This is known as the Research, Designs and
Standard Organisation (RDSO), headed by the Director General, an office of the rank of General
Manager of a Railway.
4.10 The Indian Railways have six centralized Training Institutes (CTI) including IRIMEE/ Jamalpur,
for training officers. The pre-eminent among them is the Railway Staff College at Vadodara which
conducts training courses for all the Railway Offcers. The training at the Railway Staff College (RSC)
is aimed at giving a broad understanding of the functioning of the Indian Railways the organization
structure and the tasks performed by the various departments. The other four concerned training
Institute is the Indian Railway Institute of Electrical Engineering (IRIEEN) at Nasik. The Indian
Railway Institute of Civil Engineering (IRICEN) at Pune, Indian Railways Institute of Signal Engineering
and Telecommunication (IRISET) at Secunderabad. You will be visiting these as part of your training.

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Guidelines for IRSMEProbationers, IRIMEE/ JMP

5. INDIAN RAILWAYS: Goals at a glance


(Source: A portion of the Indian Railways: VISION 2020 statement is reproduced)

5.0 By 2020, IRwould strive to


a. Establish quality of service benchmarked to the best of the Railway systems in the world.
b. Expand its route network at the rate of 2500 kms per annum. By 2020, 25,000 kms of new line
will be added and almost the entire network (barring the hill and heritage railways) would be in
Broad Gauge. This would include completion of the pending shelf of new line projects of 11985
kms. More than 30,000 kms of route would be of double/ multiple lines. Electrification of 14,000
kms of routes would take the total length of electrified route to 33,000 kms. This would include
all inter- metro links and the other busy corridors.
c. Have more than 6000 kms for quadrupled lines with segregation of passenger and freight
services into separate double-line corridors. This shall include Delhi-Kolkata, Delhi-Mumbai,
Kolkata-Mumbai and Delhi-Chennai routes. All these routes would have separate dedicated
freight corridors and high speed passenger corridors.
d. Raise speeds of passenger trains from 130 (110) kmph to 160-200 kmph on segregated routes
and speed of freight trains from 60-70 kmph to 100 kmph.
e. Virtually attain a state of "availability on demand" in freight, passenger and parcel services.
f. Design and deliver targeted services for transport of perishables, agri-produce and products of
small and medium enterprises (SMEs) such as auto-hubs and others similar clusters.
g. Target to achieve Zero accidents.
h. Target to achieve Zero failures in equipments.
i.

Utilize at least 10%of its energy requirement from renewable sources and institute a foolproof
eco-friendly waste management system.

j.

Complete 4 high speed corridors (of 2000 kms) and plan development of others.

Table- 15: Summary of broad goals


Broad category

Short Term Target


(2010-11-2011-2012)

Doubling (including DFC)


Gauge conversion

1000 kms
2500kms

Long- term Target


(2012-2013-201920)
11000 kms
9,500kms

New line
Electrification
Procurement of wagons

1000kms
2000kms
33909

24,000kms
12,000kms
255227

11

Total Target
12,000kms
12,000kms
25,000kms
14,000kms
289136

Guidelines for IRSMEProbationers, IRIMEE/ JMP


Procurement of
diesel locomotives
Procurement of
electric locomotives
Procurement of
passenger coaches
World-class stations
(Bid-out/ concession)
High-speed Corridors

690

4644

5334

555

3726

4281

6912

43968

50,880

12 Stations

38 Stations

50 Stations

2000kms

2000kms

5.1

Attainment of the goals set out above would also call for concerted action on a few key areas on
a mission mode. Critical mission areas would, among others, include technology, development of
human capital and a culture of innovation. This has been elaborated in some detail in Chapter-VI.

5.2

Needless to mention, adequate resources must be found to implement and attain the ambitious
goals set out above. This has been dealt with at some length in Chapter VII.

5.3

Broad areas of capacity enhancement and modernization to achieve the above goals along with
a very rough and tentative assessment of the magnitude of investment needed are shown in
Annexure-II in terms of Short-term (2010-2011 - 2011-2012) and Long-term (2012-2013 - 20192020) plans. The operational strategy to translate the vision into action has been spelt out in
Annexure-III.
FIVECRITICALFACTORSTHAT WILLHELPATTAIN THEVISION:
The vision is based on the high growth and high market share strategy for freight, passenger and
parcels. Growth will be achieved through highly satisfied customers. The shortage syndrome will
be consigned to history. This will critically hinge on the following:1. Capacity bottlenecks must not constrain growth. Adequate investments will be directed
towards building capacity through network expansion, doubling/ quadrupling gauge-conversion,
speed-raising, last-mile connectivity and traffic facility works.
2. Optimal mix of internal, budgetary and extra-budgetary resources will be found for this
purpose.
3. Efficient project execution to ensure efficient utilization of resources and completion of
projects within targeted time and cost would hold the key.
4. Near- total level of safety, efficient utilization of assets and infallible levels of reliability of the
system benchmarked to the best in the world through predictive and diagnostic tools and highly
trained and motivated employees.
IT tools would be used to enhance customer satisfaction, maximize productivity of assets and
improve governance.

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Guidelines for IRSMEProbationers, IRIMEE/ JMP

6 . INDIAN RAILWAYS: Critical Mission Areas (Chapter 6 of the VISION 2020)


Removal of infrastructure bottlenecks, creation of adequate capacity, design and delivery of highly
efficient market-driven services and safety and reliability of operations are critical elements of the
plan to attain the high growth goals outlined the Vision. Equally important would be the aspect of
building institutional and organizational capacity to deliver on these goals. These areas will be taken
up in a mission mode.
6.1 Infrastructure
Capacity augmentation on the scale required for the Vision (outlined in Chapter V) would not only
require massive resources but also call for organizational and project-execution challenge of an
unprecedented magnitude. Procedures pertaining identification, appraisal, approval and execution
of projects would be streamlined. Planning and project-execution process would be reorganized
and reoriented to implement and deliver whole projects (for instance, an entire route, rather than
small fractions at a time) strictly within the targeted time and budgeted expenditure. Operationally
necessary high-priority projects would be identified, sanctioned and assured full funding. PPP
would be used to the maximum extent for efficient execution of projects in areas like world-class
stations, cold-chain facilities and connectivity to ports.
In the short to medium term, the emphasis would be on quick- payback projects such as freight
bypasses, terminal and line capacity works and opening of alternate routes to ease congested
corridors. The long-term goal would be to segregate freight and passenger corridors on major trunk
routes and raise the speed and efficiency of operations on both routes.
6 .2 Safety Zero tolerance for accidents
In 10 years time, Indian Railways would target to banish accidents from its operations. This
would be achieved through a combination of technological and HR interventions. Renewal,
replacement, upgradation and technological aids for early detection of flaws and mechanized,
integrated maintenance of both track and rolling stock would be planned and managed from the
standpoint of attaining the goal of zero derailments. Crash and fire worthiness of coaches would
be enhanced. Advanced signaling technology (such as automatic verification of train movement and
line occupation through track circuiting/ axle counters, Train Protection Systems and Anti Collision
Devices) would be used in combination with training of station and running staff to eliminate
collisions. Communication, inter-locking and warning devices at manned level crossing gates would
be improved. Unmanned level crossing gates would be progressively manned or protected or
replaced by subways, Road Over Bridges and Under Bridges (ROB & RUBs) in the next five years'
time. Fencing of trucks at vulnerable locations will be undertaken to eliminate the possibility of
trespass into the track.
Security on stations and running trains and patrolling of tracks on vulnerable areas would be beefed
up to safeguard passengers and rail-users from the threat of accidents arising from miscreant
activities.
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Guidelines for IRSMEProbationers, IRIMEE/ JMP


6.3 Technological leap
Role of technology in an industry like Railways can not be overstated. Technology plays a crucial
role in enhancing productivity, asset life, safety and reliability of operations as also the interface
and experience of customers. It is also a source of significant cost and competitive advantage.
Some of the key areas for which technological solutions would need to be found include improving
the comfort of passengers, in particular, second- class passengers, development of green toilets
and safe, clean coaches, double -decker inter-city trains, improvement in the payload/ carrying
capacity of freight rolling- stock, improvement in safety and reliability of operations, raising the
speed of trains and interface with passenger and freight customers. Technology can also be used
for mechanized cleaning of trains and stations while conserving water and for adopting sound
waste-management practices. The key challenges in technology are:
a. Adoption of the best, state-of-art and cost-effective technologies in all facets of railway
operations, construction and maintenance of infrastructure and rolling stock, use of information
technology to monitor performance and improve the ease and access in using railway services
on the part of customers,
b. Finding the most optimal route of adoption and diffusion of technology;
c. Adaptation of technology to Indian conditions and continuous upgradation to stay ahead of the
race in the technological cycle;
d. Recruitment and training of employees for continuous upgradation of skills to match the
requirement of challenging pace of change in technology;
e. Ushering in a culture of innovation and inventiveness; and
f. Use of technology to continuously achieve cost innovation and reduction in cost of operations.
6.3.1 Compressing the technology cycle
In the past, Indian Railways has adopted the route of technology transfer in several areas such as
electrification, signaling, manufacturing of locomotives and components, construction and
maintenance of track. It has successfully adapted these technologies to Indian conditions and
trained its workforce to use the technology effectively. It has also innovated in respect of several
areas of asset maintenance, freight rolling stock and information technology, but IR has generally
been a late adopter of the leads and strides made in technology. A conscious strategy to mitigate
the risk of obsolescence and continuously stay ahead in technology race would be put in place. This
would be achieved by fostering close linkage between ROSa, functional levels of railway
administration and intellectual resources at premier technology institutes like IIT and NITs and
research laboratories of CSIRand DRDO along with targeted investments in R&D. In ten year's time,
IRwould be transformed from a net technology importer to technology exporter.
6.3.2. Development of Indigenous capabilities
In most parts of the world with the developed railway systems, technology leadership has generally
been achieved through investments in R&D and a vibrant railway equipment industry in the private
sector. In our country, this is missing at present. Public Private Partnerships (PPP) and close linkage
with private industry would be used to match and surpass the technological capability of the best
of the world's railway systems. By 2020, IRwill aim at not only sourcing nearly all its requirements
from domestic sources, but also relying on entirely indigenously developed state-of-the art
technologies. This would enable establishment of a vibrant and globally competitive rail component
and equipment industry in the country.
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Guidelines for IRSMEProbationers, IRIMEE/ JMP


6.4 Human capital
Railways have established an unblemished reputation of being a model employer. It has attracted
and retained some of the best civil service and engineering talent in the country to man its
managerial cadres. However, in the face of stiff competition for talent in the country, especially
from the highly competitive private sector, Railways can not remain complacent on this score.
Government ownership confers certain advantages and entails certain disadvantages in this
respect. A government job is still regarded attractive but government can not compete with private
sector on compensation. The only way to attract and retain talent is to provide a very challenging
and stimulating environment where talented employees can r~alize their full potential, contribute
to the growth of railways and take pride in the public service ethos of the organization. Only vibrant
and growing railways can provide that attraction.
As a part of the Human Capital Mission, the requirement of jobs at various levels will be assessed
and mapped. Recruitment of the right kind of talent, training, grooming and career planning of
employees linked to performance and the challenges facing the organization will form part of the
Mission. An optimal mix of external and in-house training as well as collaboration with topmost
management and technical Institutions will be used to achieve the mission's objectives.
Infrastructure at IR's training facilities will be strengthened and augmented to meet the challenge
of capacity-building for anticipating and managing change, building, operating and continuous
upgrading a market- focused and technologically sophisticated railway system.
6.4.1 Industrial Relation
Management of industrial relations in Railways is underpinned by some exemplary systems like
Permanent Negotiating Machinery (PNM) and Participation of Railway Employees in Management
(PREM). These systems would be strengthened and used to achieve consensus and generate
necessary organizational synergy towards attainment of the ambitious goals.

6.4.2 Innovation
A climate in which innovations are encouraged and rewarded would constitute the third pillar of
the management of the human capital. Railways would institutionalize a system to receive
innovative suggestions from all quarters- employee, citizens and railway users. These needs would
be evaluated and proponents of useful ideas selected for execution would be suitably rewarded. An
Innovation Incubation Cell with a dedicated and replenishable fund would be set up to take up
follow-up on innovative ideas received from all quarters to their logical conclusion.
6.5 Carbon mitigation and carbon credits
Railway is a highly energy-efficient and eco-friendly mode of transport. The objective of the Mission
would be to strengthen the advantage to the furthest limits. The mission would set challenging
targets for carbon productivity and devise a road-map to achieve the same in a cost-effective
manner. The roadmap would aim at making railway's operations environment-enhancing at an

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Guidelines for IRSMEProbationers, IRIMEE/ JMP


aggregate level. In other words, infrastructure creation and railway operation would not make any
draft on the environmental resources and on the other hand would over compensate the
environmental damage caused by transport activities by adopting green technologies. Every facet
of railway's operations and infrastructure will be critically reviewed from this angle. Indian Railways
has already taken several measures to perform its responsibility towards climate protection. Some
of these measures are:
a. New trains that have been introduced in Mumbai's suburban section e-quipped with
regenerative braking features. These have shown energy regeneration, while braking, to the
tune of 35-40%of energy used for hauling these trains.
b. To take advantage of the Clean Development Mechanism (COM) framework, Indian Railways
has developed, in association with the World Bank, a Project Design Document (PDD) for
registration with UNFCCC. The project is expected to result in reduction of 100,000 (approx.)
tons of C02 emissions per annum. It has received Host Country Approval.
c. For sensitization of railway employees on their responsibility towards the environment, Indian
Railways has taken up a project for replacement of energy inefficient incandescent lamps with
energy efficient Compact Fluorescent Lamps (CFLs) in railway quarters. As many as 26 million
CFLs (4 CFLs per family) will be distributed to railway employees residing in railway quarters free
of cost, upon surrender of equal number of incandescent lamps. This is expected to reduce 0.14
million ton of C02 emissions per annum. The project is entirely financed with the carbon credits
earned under COM framework.
d. Light-weight stainless steel coaches with enhanced passenger carrying capacity and new designs
of freight stock are being developed with higher payload to tare ratio.
e. Production of high-horse power, fuel-efficient EMO design of locomotives at Diesel Locomotive
Works (OLW) has been increased and complete switch-over to the manufacture of these
locomotives has been planned.

In the coming decade, Indian Railways envisages big initiatives as part of the National Action Plan
on Climate Change: the Diamond Necklace of Dedicated Freight Corridors and the High-Speed
Passenger Train Corridors. Both have the potential to reduce millions of tons of C02 emissions per
annum. It also envisage setting in motion the following initiatives:
i.Harnessing both existing tools (like COM) and emerging tools like Nationally Appropriate
Mitigation Actions (NAMAs) for transfer of technology as well as financing.
Energy Efficiency - up to 15% energy saving is achievable in Indian Railways. Achieving
ii.
maximum energy efficiency in traction (which accounts for 87% of energy consumed by Indian
Railways) as well as non-traction use will receive the highest priority.
Inducting new generation locomotives and rolling stock that use less energy and less
iii.
material.

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Guidelines for IRSMEProbationers, IRIMEE/ JMP


Energy audits would be carried out to improve energy efficiency on thousands of its
iv.
stations and offices. LED lighting and Energy Conversation Building Code (ECBC) would be
adopted.
At least 10% of energy used would be sourced from renewable sources such as solar
v.
power and biomass.
Indian Railways would vigorously implement a policy to procure only 3-star or highervi.
rated products for achieving energy efficiency. Henceforth, all Indian Railway's Vendors,
partners, SPVs and projects are going to be eco-friendly and climate compliant with exacting
standards.
Railways will also undertake a massive plantation drive along the Railway tracks, in
vii.
railway colonies and use grass-turfing as a protective anti-erosion measure on the slopes of the
banks along the track.
6.6 Public private partnerships
To achieve the mammoth task Railway has set itself, it has to concentrate on its core activity of
creation of railway infrastructure and operations and forge partnerships with private sector to do
the rest. The challenge of project execution and efficient provision of service can not be
accomplished without involving private sector in a big way. However, the activities and projects to
be opened for private participation have to be carefully selected and structured for their
amenability to market-based incentives and smooth execution. Several areas currently identified
for execution through PPPsuch as redevelopment/ development of world-class stations, high-speed
corridors, setting up of Multi-modal Logistics Parks, Kisan Vision projects, expansion and
management of the extensive network of Optical Fiber Cables (OFCs) and big infrastructure
projects like new lines and Dedicated Freight Corridors, rolling-stock manufacturing units, Multifunctional Complexes at stations and port connectivity projects would need to be developed and
awarded on a mission mode. To be able to do so, Railways would have set up dedicated project
organizations who would work with model documents and streamlined procedure within the
framework determined by Government of India.
6.7 High Speed Corridors
India is unique and alone among the major countries of the world in not having a single high-speed
rail corridor capable of running trains at speeds of over 250 kmph. High speed corridors have
played a major role in revitalization of Railways in Japan and Europe. Of late, high speed-rail
networks are also getting built in China, Taiwan and USA. Indian Railways would follow a twopronged approach in this respect. The first approach would be to raise the speed of segregated
passenger corridors on trunk routes using conventional technology to 160 to 200 kmph. The second
approach would be to identify a number of intercity routes, depending on viability, and build stateof- the-art high-speed corridors for speeds up to 350 kmph through on PPP mode in partnerships
with the State Governments. Partnerships with the State Governments would be crucial as realestate development would be a key element of viability of these high-cost projects. By 2020, at
least four corridors of 2000 kms would be developed and planning for 8 other corridors would be in
different stages of progress.
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Guidelines for IRSMEProbationers, IRIMEE/ JMP

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Guidelines for IRSMEProbationers, IRIMEE/ JMP


6.8 Organizational Reform
Professional support would be sought to study and analyze the present organization structure and
suggest a roadmap for reorganization to integrate the numerous services and departments into a
cohesive organization, committed to the Vision and capable of delivering on the challenging goals:
Internal reform through decentralization of decision-making and empowerment of the Zonal and
Divisional lands in financial and project execution matters with accountability for results would be
undertaken. Reorganization in terms of business lines such as infrastructure, freight, passenger
parcel and other auxiliary services could be examined. Activities other than core transportation
activities could be corporatised to bring in the needed business focus and managerial autonomy
drawing on lessons from successful past examples like CON COR, RITES, IRCON and IRFC, to name a
few of the PSUs of Railways, which have created enormous value for the Government after
corporatisation. The ongoing process of Accounting Reforms is seized of the issue of activity-wise
costing and will aid accounting separation these activities. By 2020, concrete steps will have been
taken to manage each service as a separate and distinct profit centre. The reform will also
specifically address the issues of improvement in effectiveness and efficiency in achieving goals and
building capacity to execute projects within strict time-schedules and budgetary limits.

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Guidelines for IRSMEProbationers, IRIMEE/ JMP


7.

OPERATIONALSTRATEGY(Source Annexure-III, of VISION 2020)


Plan of Action: Short Term and Long Term
The following strategies will be adopted to attain the goal outlined in Chapter- V

7.1. Infrastructure
a. In the short to medium term, the emphasis would be to remove bottlenecks and create capacity
quickly.
b. This would be achieved by providing freight bypasses in the large cities, by identifying and
completing traffic facility works such as splitting of block sections, removal of conflicting
movements and improvement of terminal facilities etc. Simultaneously, effort would be
directed towards opening alternate routes to the busy routes through gauge conversion or by
closing missing links, if any. In the long run segregation of passenger and freight routes on HDN
and substantial segregation on most of the busy routes would be the goal. Dedicated freight
corridors and speed raising projects on the passenger corridors would be completed in a timebound manner.
c. Project execution capability would be strengthened.
d. Port connectivity works would be taken up on priority in partnership with ports and other major
users.
e. A non-Lapsable dedicated fund will be set up to fund new line projects and wipe out the
entire throw forward of new line projects. A mechanism for mobilizing the support of State
Governments towards capital costs and sharing of operational losses will be institutionalized.
f. Connectivity projects to the North-East (new line and gauge conversion) and J&K (new line)
would be accorded priority. All state capitals would be connected by rail.
g. Segregations between commuter and non-commuter lines in large cities with population
exceeding one million shall be achieved by partnership with state governments and city
authorities.
h. All construction projects would be executed by use of modern technology and construction
equipment.
i. Emphasis would be to create maintenance-free, economic and durable assets. Mechanized
maintenance would be adopted to maintain the health of the track assets and provide reliable,
uninterrupted service.
j . PPP will be used for efficient execution of projects especially in areas like construction of
world-class stations, multi-modal logistics parks, cold-chain facilities and connectivity to ports/
industrial clusters.

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Guidelines for IRSMEProbationers, IRIMEE/ JMP


7.2. Marketing
a. Freight- Railways would concentrate on strengthening its presence in the bulk traffic segments
and container cargo i.e. in commodities it already serves and attracting new commodities like
fly ash, automobiles etc. through partnership with private sector freight operators. Special
mini-or two-point rake services will be designed. Special-purpose rolling stock suited to meet
the specific requirements of commodities will be inducted. These will be encouraged through
Liberalized Wagon Investment and Leasing Scheme. Long-lead traffic will be courted with special
effort.
b. Passenger - In the passenger segment, the enhanced capacity of the system would be used to
raise speeds and fully satisfy the demand for passenger travel. Services will be progressively
upgraded. Distribution channels for railway tickets would be constantly innovated so that
obtaining a railway ticket is completely hassle-free. PRS/ UTSterminals, e-ticket services, tickets
through post offices, ATMs, petrol pumps and smart-card based tickets for unreserved travel
would be expanded to improve access. New and emerging technologies will be harnessed
towards this end.
c. Periodic and regular passenger/ market surveys would be conducted. The results will be used
to redesign services and delivery. IT tools would be used to develop - Customer Relationship
Management (CRM) and Yield Management Systems.
7.3 Freight Business
a. The emphasis would be to meet the exacting needs of customers in terms of timeliness and
quality of service. Time-tabled and guaranteed- delivery freight services would become the
norm. Freight services will also be designed to meet pre-determined schedules of customers.
Dedicated freight corridors will greatly help in achieving this goal.
b. There would be a constant stress on cost efficiencies through reductions in terminal and en
route detections and rationalization of carriage and wagon examinations.
c. Loyal customers who transport their cargos from siding to siding on rail and contribute to the
efficiency of operations by installation and operation of efficient freight terminals and handling
systems would be incentivised by sharing a part of the efficiency gain with them.
d. Freight terminals and sidings for use of multiple users will be encouraged.
e. Tariff-setting would be a dynamic and market-based exercise.
f. Rolling stock with high payload to tare ratio (at least 3.5 vis-a-vis 2-2.5 now), tailored to the
needs of customers would be developed and deployed.
g. IT-based MISand customer relationship management (CRM) systems would be adopted for inter
alia, paperless transaction for indenting, freight payment and invoice forwarding as well as real
time tracking of cargo.
h. Average speed of freight trains would be improved from 25 to 50 kmph.

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7.4.

Passenger Business

a. Passenger business will be reorganized into three distinct segments, namely, fast intercity, slowmoving passenger and suburban. A separate organization for sub-urban business, replacement
of conventional rolling-stock of the slow passengers by MEMU/ DMUs and a range of fast
services including high-speed services would be the thrust of the policy.
b. 50 stations already announced for development into world-class stations through PPP would
be completed and more would be taken up. Multi-functional complexes will be developed at 50
stations to provide the passengers with high-quality services and amenities.
c. 375 stations identified as Adarsh Stations would be developed and provided with all modern
amenities like drinking water, toilets, waiting rooms, dormitory and modern train indication,
displays and signages.
d. Terminal capacity will be built up to match demand. Modern maintenance terminals
equipped with automatic coach washing plants, train preparation facilities, sustainable waste
management systems, all- whether pit lines, mechanized checking, detection and repair systems
would be installed.
e. Maximum permissible speeds for premium passenger trains would be improved to 160-200
kms on the segregated passenger corridors. High speed point-to-point services and overnight
connectivity between national and state capitals and between state capitals and other major
cities would be provided at regular frequencies.
f. High-capacity coaches with optimized ergonomic design and double-decker coaches for intercity
trains would be developed. Seats/ berths in the coaches would be innovatively designed to allow
for flexible use for both day and night travel.
g. Popular trains would be augmented to 24-26 coaches.
h. Adequate rolling stock would be inducted for suburban services. Air-conditioned EMUs would be
introduced.
i.

Real time online enquiry system would be universalized.

j . Quality of catering would be improved by adopting sound and proven business practices, setting
up a chain of modern base-kitchens and branded restaurants at stations and encouraging
innovation and local cuisines in on-board catering.
k. Sanitation and waste management at stations will receive high priority. Each station would be
studied for its peculiarities and a well thought out plan will b~ devised to achieve near-zerowaste by adopting the principle of reduction, recycle and re-use and improve the cleanliness of
the stations benchmarked to the best in the world. Performance criteria and standards will be
evolved for each element of cleanliness and achievement of these standards will be monitored
at all levels. A unified system of responsibility for cleanliness at stations with adequate financial
and oranisational resources will be put in place. Infrastructure and amenities like water supply,
drainage, sewerage, washable aprons, properly designed platforms and 'pay and use toilets'
maintained by competent agencies along with user awareness campaigns will form part
of the plan. Coordination with city authorities will be maintained to achieve this objective.
Cleanliness of trains would be enhanced by retrofitting all coaches with discharge free green
toilets, mechanized cleaning at maintenance terminals, onboard housekeeping and en route
mechanized cleaning at Clean Train Stations. Maximum recycling of water will be planned and
achieved. Professional assistance will be utilized for pest and rodent control.
l.

Quality cleaning of bed linen would be ensured through mechanized laundries.


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Guidelines for IRSMEProbationers, IRIMEE/ JMP

7.5.

Parcel
a. Dedicated parcel terminals would be set up and time-tabled super-fast parcel services would be
run.
b. The business would be segregated from passenger services.
c. Partnership would be formed with the private sector to provide end-to-end logistics. Adequate
number of parcel vans (200 per annum as against 100 at present) would be inducted annually in
partnership with the private sector. This would include refrigerated parcel vans to carry fruits,
vegetables and perishables and special-purpose rolling stock to the carry automobiles.

7.6 Rolling Stock (Mechanical)


a. Locomotive and coach manufacturing units would be modernized and augmented. The coach
manufacturing capacity at Integral Coach Factory, Perambur and Rail Coach Factory, Kapurthala
would be augmented to 1500 per annum each. New coach manufacturing units at Rai Bareily
(1,000 coaches per annum), Palghat (600 coaches per annum) and Kanchrapara (500 EMU/
MEMU/ DEMU coaches) would be commissioned.
b. Coaches with stainless steel bodies and crashworthy structural designs incorporating the most
modern occupant-protection and fire-retardant properties will be inducted. These would also be
equipped with EPbrake systems to enhance safety in high-speed operations.
c. Self-sufficiency would be achieved i~ the production of wheel sets. The existing capacity of the
Wheel Axle Plant at Bangalore would be augmented.
d. Long-term savings in cost of manufacturing would be achieved by making smart "make or buy"
decisions, developing reliable supply chains and vendors and adopting flexi/ lean manufacturing
set up.
e. Existing workshops for locomotive, coach and wagon maintenance would be upgraded;
augmented and new workshops would be set up in a need-based manner.
f. High horse power locomotives (4500/ 6000 HP against 300013300 HP) would be developed
for heavy haul freight and high-speed passenger services. The availability of locomotive for
operation would be extended to 45 to 60 days in case of ALCO locomotives and four months in
case of EMD locomotives.
g. 170-tonne cranes with telescopic jib and self propelled accident relief train would be deployed
to improve response in the aftermath of accidents.
h. Alternate fuses, such as 10%blending of bio-diesel, CNG, fuel cells and hydrogen fuel, would be
explored.
i. Onboard diagnostics and online safety tools such as wheel impact load detectors (WILD), online
bearing acoustic detectors and hanging component detectors would be deployed to improve
safety.
7.7 Rolling stock (Electrical)
a. High horse power locomotives (9000 to 12000 HP) vis -a - vis 5000 HP at present would be
developed for high speed and heavy haul operations. The loco manufacturing factory at CLW
would be expanded by setting up a new ancillary unit at Dankuni.
b. Train sets would be introduced for intercity express train services to achieve high speeds and
minimize terminal detention.
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Guidelines for IRSMEProbationers, IRIMEE/ JMP

7.8. Infrastructure (Track)


(a) Track structure
Track structure will be standardized with 60 kg, 90 UTS rails and concrete sleepers with elastic
fastenings. Improvements in specifications of materials, new types of elastic fastenings, economical
designs of concrete sleepers and modern mechanized methods of track-laying and maintenance
will be progressively adopted. Composite sleepers will be used at locations unsuitable for standarddesign sleepers or those with un ballasted deck.
(b) Speed
Tracks on identified, segregated routes would be made fit for running passenger trains at speeds
upto 160- 200 kmph and freight trains at speeds upto 100 kmph. Formations, sleeper-fittings and
bridge approaches will be specially designed and upgraded. Thick-web switches and moveable
crossings will be provided on these routes. Eventually, thick-web switches will be standardized and
the conventional curved switches will be replaced. Turnouts would be designed to permit speeds
upto 50 kmph.
(C) Rail Panels
Rails will be procured in long panels of 120 meters and would be welded in flash-butt plants
and laid with lengths ranging from 250 mtrs to 500 mtrs. Such continuously welded rails would
eliminate a large number of rail joints and, in turn, would improve rail metallurgy (i.e. minimal
residual stress, higher wear resistance, higher elongation and better fracture toughness),
maintenance and riding comfort. Corrosion resistant rails shall also be provided in corrosionprone areas. Joints will be welded in situ by portable flash butt welding plants and in exceptional
circumstances by SKV Thermit welding. Rail life will be extended by rail grinding and rail lubrication.
Improved types of switch expansion joints (SEJ) would be used in place of the conventional switch
expansion joints.
(d) Maintenance
Cost effective options for mechanized track maintenance, including by remote satellite control,
shall be explored. There will be complete mechanization of track maintenance activities. A decision
support system such as Track Management System (TMS) will be in place to optimize material,
machine and equipment and manpower inputs for track recording-cum- monitoring on the entire IR
network (including USFD cars capable of recording precisely the location of track irregularities).
Suitable techniques for data mining will be developed so that track maintenance philosophy shifts
from present "find and fix" to "measure and predict." Permanent-way engineers shall also be
provided with PDAs for recording inspection inputs.
All the maintenance and construction activities related to track shall be mechanized. Trackmen will
be equipped with small track machines also. Rail Mounted vehicles (RMV)/ Rail-cum-road vehicles
would be increasingly used to facilitate movement of maintenance units.
All the maintenance units will have communications from worksites in block sections to the control
offices. Maintenance blocks shall be taken by P-way and Bridge Engineers through mobile phones

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Guidelines for IRSMEProbationers, IRIMEE/ JMP


by software encoding. Integrated assured blocks shall be made available so that a culture of zero
defect and "no surprises" exists during operation of trains.
Human dependence in the form of push trolley inspection, foot-plating, patrolling, etc. for
detection of flaws and deficiencies in track parameters will be eliminated. It is envisaged that by
2020, the health monitoring of assets should be completely mechanized.
Vehicle mounted USFD would be stabilized by 2020 to achieve a sharp reduction in the number of
rail fractures and increased reliability of assets.
(e) Bridges
Condition of bridges shall be monitored through a Bridge Management System. All new bridges will
be on ballasted deck suitable for long-welded rails (LWR) and machine maintenance. Deflection
settlement monitoring sensors will be fixed on all important bridges to directly transmit data to
computers. New bridges and bridges on dedicated freight corridors and high speed lines will have
approach slabs.
Retrofitting of bridges (particularly arch- bridges) would be taken up.
7.9 Infrastructure (Electrical)
a) Energy-efficient, train power supply with LED lighting would be developed to improve energy
efficiency. Energy conservation measures such as energy conservation building code (ECBC)
would be adopted.
b) 2X25 KV system of overhead supply would be provided in high density routes.
c) Power plants would be set up at Navi Nagar and Adra through the existing Joint Venture with
NTPCto meet the increased energy requirements from 2500 MW to 6000 MW to reduce energy
cost.
d) 10%of the energy would be from renewable sources.
7.10 Signal & Telecom
a) Point and signal operation would be centralized at stations with provision of panels and
electronic interlocking.
b) Filament signals will be phased out. Signals will be upgraded with LED lighting to improve
reliability and visibility. Data loggers would be installed for predictive maintenance of signals.
c) Use of axle counters for block working (BPAC) would be adopted to enhance speeds and
improved transaction time in block working.
d) Station sections will be completely track circuited to enhance safety in respect of verification of
line occupation.
e) Automatic block signals and intermediate block signals would be used to improve line capacity.
f) On board train protection/ collision prevention systems such as the ACD of KRCL, would be
installed to avoid collision and driver passing signal at danger.
g) Mobile train radio communication, extension of optical fiber cable (OFC) over the entire route,
IP-based train control communication, voice network modernization and replacement of
overhead alignment with underground cables/ OFCs are among the measures to be used to
improve reliability of the communication system and enhance the capability of the transport
system.
h) Broad-band internet and multimedia facilities and high quality train information displays and
information boards at stations and running trains would be introduced to improve the quality of
passenger service.
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Guidelines for IRSMEProbationers, IRIMEE/ JMP

7.11

Security

a) Railway Protection Force (RPF) would be strengthened and empowered. Technology and HR
interventions would be used to enhance capability.
b) An integrated security system covering major railway stations with CCTV surveillance, electronic
access control, personal and baggage screening systems, explosive detection and disposal
system would be implemented.
c) All important RPFposts would be networked.
7.12

Material Management

a) Transparent and competitive procurement systems would be adopted.


b) Just-in-time system of material management would be adopted to reduce inventory costs. ITbased MISand integrated supply management would be adopted to optimize on materials lifecycle costs.
c) Activity-based requirements and zero based budgeting would be adopted.
7.13

Human Resource development (HRD)

As outlined in the Chapter-VI, HRD will constitute a key mission area. Matching of skills and
qualifications with requirement, training and motivation, through a challenging workplace environment,
incentives for accountable performance and cross-functional teamwork would form the core of IR's
HR strategy. Railways will attract, nurture and retain top talent in the country to meet the challenges
ahead.
7.14

Accounting Reforms

The ongoing process of accounting reform would be speeded up. Complete switchover to accrualbased accounting in consonance with the accounting standards stipulated by Government Accounting
Standards Advisory Board (GASAB) would be attempted. This would enable activity-wise costing that
can aid pricing decisions and management information and control systems for business lines, cost
and profit centres. This could also being the railway's accounting in line with the globally accepted
accounting standards. An extensive and state-of-the-art infrastructure of computing and data processing
network will constitute the bed-rock of the system. Computerization of earnings and expenditure at the
transaction level will be completed as a part of the effort. This exercise will be targeted for completion
by 2020.

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Guidelines for IRSMEProbationers, IRIMEE/ JMP


7.15 Information technology
IT tools will continue to underpin Railway's efforts to enhance customer satisfaction, maximize
productivity of assets and improve governance. Priorities would include improving the interface with
and providing real-time information to citizens, freight customers and passengers on various devices
including mobile phones using satellite-based in train tracking systems, introduction of paper less
mobile ticketing systems and Enterprise Management System to improve productivity and efficiency.
Roll-out of major applications like Passenger Reservation System (PRS), Unreserved Ticketing System
(UTS), Freight Operation Information System (FOIS), Rake Maintenance System (RMS) and Terminal
Management System (TMS), Control Office Applications (COA). Crew Management System (CMS),
Passenger Management System (PMS) etc. will be completed by 2010. Other components of FOISand
Passenger Management System such as Management Systems for locos, coaches, wagons, workshops
etc. will be completed and rolled out by 2011. Applications for fixed assets like track, power supply
equipment etc and ERPfor production units will be completed by 2012-13.
All IT facilities and platforms will be integrated through intelligent and inter-operable systems to enable
IR to respond with speed to customer's needs, business opportunities and external challenges. For this
purpose it will be ensured that:
All areas of infrastructure management will provide automated information systems.

Introduction of devices for all monitoring systems have to comply with providing automated
data to Management Information System.
Event capturing for business related applications having customer interface will be automated
through use of intelligent devices integrated with the applications.
Decision Support Systems will be provided in all critical areas of infrastructure management for
conducting business

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Guidelines for IRSMEProbationers, IRIMEE/ JMP

B. ABOUT MECHANICALDEPARTMENT
Responsibilities of Mechanical Department are to design, manufacture and maintain Rolling
Stock in addition to day to day affairs of divisional working. The typical organizations at various
levels are given below.
1.

ORGANISATION AT ZONALHEADQUARTERS
Chief Mechanical Engineer

(CME)

Overall in charge

(Principal HOD)
Chief Workshop Engineer

(CWE)

Workshops

Chief Rolling Stock Engineer

(CRSE)

Carriage & Wagon

Chief Motive Power Engineer

(CMPE-DSL)

Diesel Locos

Chief Motive Power Engineer

(CMPE-R&L)

Loco Operations & Relief trains

Chief Mechanical Engr/ Planning (CME-Planning)

2.

Planning Function

DIVISIONALOFFICE
Sr. Divisional Mech. Engineer

(Sr.DME/ O & F)

Loco Operation & Freight

Sr. Divisional Mech. Engineer

(Sr.DME-C&W)

Carriage & wagon

Sr. Divisional Mech. Engineer

(Sr.DME-Dsl)

Diesel Loco maintenance

On most Divisions, the divisional officers are in JAGassisted by DMEs in SSand ADMEs in JS. On
some smaller Divisions, the Divisional Officer may be in SSonly.
3.

WORKSHOPS
Chief Works Manager
Dy. Chief Mechanical Engineer

(CWM)
(Dy. CMEs)

Overall Charge
Specific functional charges

The CWM reports to Chief Workshop Engineer (Zonal HQ)


The CWM is assisted by Dy.CMEs in JAG as well as Works Mangers (WM) in SSand AWMs in JS.
Other departments have a similar set up of HODs in Headquarters and Divisional Officers on the
Divisions.

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Guidelines for IRSMEProbationers, IRIMEE/ JMP

C.

ABOUT IRIMEE
1. HISTORY
Indian Railways Institute of Mechanical & Electrical Engineering (IRIMERE) is located at Jamalpur
in the Munger District of Bihar, about 8 kilometers from Munger Town. During the era of
Mahabharata, Munger was the capital of Anga Pradesh ruled by Kama. Munger was also the
seat of Mir Kasim, Nawab of Bengal who fought the East Indian Company here. The place had
traditional skills of making firearms and hence selected by the East Indian Railway for one of its
earliest workshops. The location selected was at the foothills of Rajmahal range ( a part of Chhota
Nagpur plateau), which was high enough to survive any threat of floods from Ganga, and the hills
secured if against any organized attack from an army. The location had a tomb of Baba Jamal
Saheb, after whom the place was called Jamalpur. Jamalpur Workshop was established nearly 150
years ago, on 8th of February 1862.
IRIMEE had humble beginnings, when it started in 1905 as a technical school attached to the
Jamalpur Workshop. It came into national prominence when it started the training of Special
Class Railway Apprentices as Mechanical and Electrical engineers, starting from the year 1927.
In 1974, the school was made a centralized Training Institute (CTI), renamed as Indian Railways
Institute of Mechanical & Electrical Engineering and brought under direct control of Railway
Board. It is, therefore, the oldest of CTIs.
In 1988, the training of IRSMEProbationers was centralized under the control of Director, IRIMEE
but with HQ at Kharagpur, where there was an OSD co-coordinating the training with the Director
from 1997. HQ of IRSMEProbationers was shifted to Jamalpur.
The Institute is headed by a Director and has 22 members of Gazetted/ Non Gazetted teaching
faculty along with necessary supporting administrative and service of staff. Some of the faculty
members are directly recruited through UPSC, and others are posted from, the Zonal Railways.

2. TRAININGACTIVITIESAT IRIMEE
Training activities at IRIMEEcan broadly be grouped as below:a)Theoretical and practical training of Special Class Apprentices during their
years.

apprenticeship of 4

b) Training of IRSME probationers in their 1-1/ 2 years of attachment with IRIMEE and
introductory courses of one week duration for the probationers of other Departments.
c)Professional courses for serving officers and supervisors belonging to the Mechanical
Engineering Department.
d) Special tailor made courses, as per requirement, for Non Railway Organizations and Foreign
Railways.

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Guidelines for IRSMEProbationers, IRIMEE/ JMP

2.1 Training of IRSMEProbationers


Training of IRSMEprobationers during their 1 years of probationary period is centrally controlled
by IRIMEE. Their training mainly comprises of.

Institutional training at RSC, IRIMEE, IRIEEN, IRICEN, IRISETand IRITM .


Training at major railway organizations like RDSO, DLW, DMW, CLW, RCF, ICFand RWF.
Training in various repair workshops.
Training in various divisional units like Diesel sheds, C&W depots, Control Room etc.
Zonal Training.
Detail distribution is furnished in paras on later pages.

3. COMPUTERCENTRE:
Networking
A campus wide Local Area Network (LAN) of computers was inaugurated in 1989, which has since
been extended as Wide Area Network (WAN) to two of the hostels by using simulated leased
lines using technology developed in-house at IRIMEE. The LAN can support 76 nodes.
Internet
There is a Linux based server, which facilitates availability of Internet over the LAN, using leased
line connection. It provides accessibility over the WAN of IRIMEE, and the users do not have to
go to the computer - centre for accessing it.
IRIMEEWebsite
IRIMEE has developed a website.
This website can be visited at http:/
www.irimee.indianrailways.gov.in. Website carries information about the Institute, the
full course calendar in interactive form, instructions for participants and other such useful
information. The website is aimed at becoming a forum pf interaction between the zonal
railways, production units, and IRIMEE. The purpose of this interaction is to help mechanical
engineering department of IR is continuously improve its performance, thereby helping in
improved performance of Indian Railways as a whole.
Section of the Website

Spirit of Jamalpur
Hindi
Search
About
courses
Knowledge Bank
Discussions
Information
Tenders
Gymkhana SAM

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Guidelines for IRSMEProbationers, IRIMEE/ JMP


4. LIBRARY
(1)

Presently the Library has a stock of about 18,500 books. In addition to these, there is stock
of RDSO and other Railway Related documents. The entire collection contains books of
Mechanical, Electrical, Electronics and Computer Engineering disciplines, Management and
other subjects of Science & Technology. There are books on Indian Railway Codes/
Manuals, Standards, specifications, reports, various publications of Railway Board and other
Railway Organizations. There are also books on Humanities stream such as language,
literature, history, geography, economics and other branches of social science.

(2)

The library subscribes a good number of Indian and foreign periodicals of technical nature
and general category.

(3)

In recent time, a collection of non-print media such as CDs, VCDs and DVDs has also been
developed.

(4)

Transaction of documents and document-search facilities are provided through


computerized system. Online Public Access Cataloguing (OPAC) having multiple access
prints for search is available and required information can be retrieved through any
Computer/ Terminal connected with Institutes LAN.

(5)

The Library provides Multimedia Room, Reading Room (Periodicals & News-papers). In
house study kiosk, Document (General Category) Transaction and reference query services.

(6)

A separate collection of Indian Railway Codes, Manuals, Reports and other important
Railway related documents has been developed.

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Guidelines for IRSMEProbationers, IRIMEE/ JMP

D.

IRSMEPROBATIONERS TRAINING
1. Distribution of 78 weeks:
COURSE/ UNIT

Code

Weeks

OTHER THAN MECH RAILWAY UNITS


Foundation Course at RSC/BRC

10

Induction Course at RSC/BRC

IRIEEN

IRISET

IRITM

IRICEN

Industrial Visit

IT for Mechanical Dept at CRIS

ITCR

Parliamentary and Railway Board

1
1

COURSES AT IRIMEE **
Introduction to Railways-C&W

CWIN

Introduction to Railways-Traction

DTIN

Power Electricals & their Control Systems

PECS

Mechatronics

MEKX

Common Maintenance Practices in C&W

CMCW

Coaching Maintenance Practices

CHGM

Diesel Fundamentals

DFUN

Diesel-ALCO Loco Systems

DSAL

Diesel-GM Loco Systems

DSGM

Diesel Maintenance Management

DMMT

Diesel Tech - Others

DTOT

Fuel, Loco Ops and Crew Management

FLOC

C&W Operations in Divisions

CWOD

Workshop Management

WMGT

Mechanical Specific CMT Issues

MCMT

Disaster Management

DISM

Money value cases in mechanical

MVCM

Mechanical specific Material Planning

MSMP

Mechanical specific Management Skills

MSMS

IT in daily Use

CIDU

32

Guidelines for IRSMEProbationers, IRIMEE/ JMP


COURSE/ UNIT

Code

DLW

Weeks
1

DMW (Plus Course on CNC machines)

RCF (Plus Course on SS welding, laser tech & robotics)

ICF

RWF (Plus Course on Automation in manufacturing)

CLW

COFMOW

RDSO

LHB Coaching Depot @ NDLS/ Mumbai

C&W Workshop @ JUDW

Wagon ROH @ UMB/ NKJ

Private Wagon Maintenance BLC @ TKD

Wagon PU (ASR)

Crane Manufacture and POH @ JMP

Diesel POH @ PL

Diesel Shed GM loco and Ghat Section Working @ Hubli

Diesel Shed ALCO @ VSKP

DMU Shed @ JUC and Srinagar

MLR @ BPL and CAMTECH @ GWL

Heritage @ SML/ Ooty/ Darjeeling

Coaching Depot

Wagon Yard

Wagon ROH

Divisional Control (Power and C&W)


Zonal Head Quarter (CNLs, Mech, Stores, Account, Civil,
Personnel, General, Vigilance , GM)
Diesel and DMU Shed

Work Shop

Joining

Interim Reviews

Final Exams, Interview, Passing Out

TOTAL

**:

78

Each one week course at IRIMEEwill follow by an examination. The weightage of each will

be 20 marks. First completion of any 10 courses will be considered as the completion of Phase I
and the completion of remaining 10 courses will be considered as completion of Phase-II.

33

Guidelines for IRSMEProbationers, IRIMEE/ JMP


2.

Training Procedure Important points to note


The IRSMETraining Schedule for 78 weeks is given on the previous page. You should collect your
training programme dates well in advance.
Please note following important points regarding field training:a)

During your training you must maintain a diary and keep it up dated at the place of Training
& get it signed by the Training In charge on spot. Weekly feedback of the field training may
be mailed at prstirimee@gmail.com. You may be asked any time to produce your training
diary by an officer who is directly or indirectly related to your training. The objective of
keeping a Diary is to facilitate you in noting down important observations, points,
information on shop floor, field depot, footplate or other workplace.
At the end of the training course you should collect Attendance cum Release Letter from
the field units and the same is to be produced at IRIMEE/ Jamalpur without fail.

b)

You will be given guidance regarding what to observe, to do, study & find out during your
field training. However, how much you learn during this training will depend a lot on your
own initiative also.

c)

Remember that you can learn the most when you are on training. Do not hesitate to ask
questions from not only senior officers but also from supervisors and junior staff. They are
the people on the job and know their particular job better than anyone else. Most senior
supervisors like senior section engineers and section engineers have usually put 20-30 years
of service and due regard should be given to their experience and expertise. Always treat
your senior subordinates with respect. How well are you trained in the field units depends
entirely on how active are you and how many questions you ask.

d)

Every place you visit will have an Officers Club. It is in your own interest that you take active
part in the Club activities as you will get to know and will be able to interact with other senior
officers.

e)

When you visit a field unit, you must report to in charge of the field unit before meeting
Training In_charge of the unit.

f)

The guide lines given by Field In_charge and Training In_charge will have to be followed in
addition to guidelines given to you by IRIMEE.

g)

Inform IRIMEE about your reaching the place of training. On the 1st day of reporting to field
unit you must convey the name & contact numbers of the unit head and the training
in_charge to the IRIMEEby email and/ or by phone without fail.

h)

You must ensure regular attendance in the field unit during office hours.

34

Guidelines for IRSMEProbationers, IRIMEE/ JMP


i)

After you report back to IRIMEE in between your courses, you will be required to present,
whatever you have learnt during your total field training in different training modules. The
concerned faculty will interview you.

j)

You will be given a major project in the beginning of the training. The project report will
have to be submitted to the Director before completion of 70th week of training.

k)

Uniform: You must wear as per the respective note.

k)

Bond
You are required to submit a Bond, details of which will be given to you. This is necessary
since the Railways will be spending a fair amount on you for your training and the Railway
rules require such a bond to be submitted by you. Please complete and submit the bond
without delay.

l)

Probationary training & Seniority


The Railway Board letter governing the probationary training is furnished below in next para.
+ Your seniority within your batch will be decided as per para 8 of Rly. Boards letter No.(TRG)
89 (13)/ 3 dated 15.9.92, which is being copied below. You will appreciate that about one
third of the weightage for the fixation of your seniority is based on your evaluation while you
are on probationary training.

35

Guidelines for IRSMEProbationers, IRIMEE/ JMP

3. Railway Board-Policy Circular Letter:

(COPY)

GOVERNMENTOFINDIA, MINISTRYOFRAILWAYS(RAILWAYBOARD)
No. E(TRRG) 89 (13)/ 3

New Delhi-1, Dated: 15.09.1992

The General Managers,


All India Railways, Including Production Units,
Metro Railway and Railway Electrification/ Allahabad.
Chief Administrative Officer, Diesel Component Works, Patiala.
Principal, Railway Staff College, Vadodara.
Directors,

Sub:

Indian Railways Institute of Civil Engineering, Pune.


Indian Railways Institute of Mech. & Elect. Engineering, Jamalpur.
Indian Railways Institute of Signal Engg. & Telecommunications, Secunderabad.
Indian Railways Institute of Electrical Engineering, PBNo.33, Nasik Road, Nasik.

Probationary Training of Group A Probationers of Various services controlled by


Ministry of Railways.

1. Board have decided to curtail the probationary training of probationers of Group A services of
all departments excepting IRAS, RFP and Medical from 104 weeks to 78 weeks. Consequently in
super session of instructions contained in Boards letter No. E (TRG) 86 (13)/ 3 dated 1/ 3-7-87, the
following revised instructions on probationary training and other related issues are prescribed.
2. Scope of Applicability:
The instructions contained in this letter will be applicable to the probationary who join on the
basis of 1991 examination and report for training thereafter who joined as SCRAs on the basis
of 1988 examination batch and thereafter. These instructions will, however, not be applicable
to Group A probationers of RPF, Indian Railways Medical Services and Indian Railway Accounts
services. For these services the existing instructions in gouge swill continue to be applicable.
3. Period of probation:
The total period of probation, probation of training and probation against working post would
be as under:SERVICE
TRAINING
IRSME, IRSE
IRSSE, IRSEE
IRSSAND IRTS
IRPS

ON PROBATION AGAINST PROBATION PERIOD OF TOTAL


WORKINGPOST
PROBATION
1.5 Years
1.5 Years
3 Years

1.5 Years

0.5 Years

36

2 Years

Guidelines for IRSMEProbationers, IRIMEE/ JMP


3.1 The revised training schedules of 78 weeks for various services are attached at Annexure 1 to
Annexure VII.
4. Centralized Training of Probationers:
The probationary training of probationers of different Group A services has been centralized
with the Centralized Training Institutes as under:INSTITUTION
FOR
CENTRALLY SERVICE
CORDINATING/ MONITORING
PROBATIONARYTRAINING
IRICEN, PUNE
IRSE
IRIMEE, JAMALPUR
IRSME
(Engg. Graduates and SCRA)
IRIEEN, NASIK
IRSEE
IRISET, SECUNDERABAD
IRSSE
RAILWAYSTAFFCOLLEGE, VADODARA
IRSS, IRTS, IRPSAND IRAS
4.1 The officers in-charge for central co-ordination and monitoring of the probationary training
of various services designated as Training Director will look after all aspects of training Viz:
practical/ institutional.
5.

Extension of joining time: No extension in joining time to any candidate appointed to Group A
service under the Ministry of Railways as a result of Engineering Services Examination or Combined
Civil Services Examination, will be given. Henceforth, all probationers of a particular service will
be advised to join on a specified date. The specified date will be 1-2 weeks ahead of the date of
commencement of Foundation Course at Railway Staff College, Vadodara. Thus all probationers of
a particular batch and service will commence their probationary training and complete their training
together.

6. Maintenance of Diary etc. by probationers:


During the period of probationary training, the probationers shall maintain a Diary to indicate
their day-today activity which should be checked periodically by the Training Director during
probation.

7. Confirmation after probationary training:


No probationer will be confirmed in Junior Scale unless he/ she has successfully passed all the
examinations prescribed after completion of institutional/ training as well as posting examination
and confirmation test now being prescribed in lieu of Departmental Examination at the end of
probation against working post.
8. Determination of Seniority of Group A Probationers of different services in Junior Scale after their
confirmation:
37

Guidelines for IRSMEProbationers, IRIMEE/ JMP


The performance of Group A probationers during the probationary training will be evaluated and
marks will be awarded for each time of probationary training. The maximum marks for different
items of probationary training will be as indicated in Annexure A.
8.1 The inter seniority of Group A probationers of a particular examination batch and of a
particular service, on their confirmation to junior scale, will now be decided on the basis of marks
obtained by them during the probationary training as indicated in Annexure A and marks obtained
by them in the UPSCCompetition (or during the apprenticeship training for SCRAs). For the purpose
deterring seniority in accordance with the revised procedure, probationers merit position should
be adjudged on the basis of marks secured by them out of maximum marks 3300 the maximum
marks of UPSC Competition would be 2050 and the maximum marks for performance during
probationary period will be 1250.
8.2 In case of Engineering Services Examination, the maximum marks of UPSC Completion are
1200. Therefore, for the purpose of determining seniority on the basis of above norms, the marks
obtained by the candidates in the Examination may be normalized by the multiple by a factor of
2050/ 1200 = 1.71083. Similarly, in case of SCRAs the maximum marks permissible during their 4
years apprenticeship period are 2400. The marks scored by them may be normalized by multiplying
by a factor of 2050/ 2400 = 0.854.
8.3 The record of marks obtained in various items by each probationer during probationary training
shall be properly maintained by the Institution controlling centralized training. The concerned
institution will also be advised by the Ministry of Railways and marks obtained by each candidate in
the UPSC Examination (by each SCRA in his/ her apprenticeship training). To enable Railway Board
to determine interse seniority of probationers of the batch, the concerned institution controlling
the training will also send details of the marks obtained by each probationer of a particular batch
and seniority of the following performa arranged merit wise, when six months of completion of
probationary training. The record should be sent under a sealed cover addressed to the Secretary,
Railway Board (by name). Proper secrecy should be maintained at every stage.

12.

13.

Total Marks

Total marks secured in


probationary period
(Col. 4+5+6+7)

Assessment

Normalized marks
secured in UPSC
Competitions/
Apprentice Training

Posting Examination

Name

11.

Trg. In Prof. Instt. in


Prof. Areas

10.

Foundation
&
Induction

9.

S.No

Marks secured during Probationary period

14. Departmental Examination;


In place of existing practice of periodical departmental examinations during the probation period,
henceforth there would be only one examination consisting of written and viva/ voce test after
38

Guidelines for IRSMEProbationers, IRIMEE/ JMP


completion of prescribed probationary training and this will be called the POSTING EXAMINATION.
This examination would be conducted by the institute where the probationary training has been
centralized Para 2 above).
9.1 Confirmation Test:
There would be a viva-voce test at the end of the probation to determine suitability for
confirmation. The viva-voce test would be conducted by a committee of 3 PHODs and Director
or his nominee of Centralized Training institute concerned controlling the probationary training.
Assessment of this committee will be taken into consideration for the satisfactory completion of
probation and confirmation of the candidate. If the officers performance in the assessment is
considered inadequate, the probation period could be extended.
9.2 The training Director will invite senior experienced officers from various railways to set and
evaluate the papers and to conduct viva examination so as to maintain a high standard of objectivity
in evaluation. He/ She will also seek the advice of the various Railways to update and modify the
syllabus etc. for written test.
9.3 Honorarium shall be paid to the officers for setting the papers, evaluation etc.for the positing
examination at the same scale as is applicable to officers for similar jobs for thje departmental
examination for IRASProbationers.
9.4 Grant of Advance increments to probationers:
Due to introduction of only one examination at the end of probationary training i.e. posting
examination, in place of existing periodical departmental examination, the system of grant of
advance increment will be as under:1st Advance Increment : Successful completion of Foundation/ Phase -I, whichever is earlier

2nd Advance Increment : Successful completion of Induction/ Phase-II/ Posting Examination,


which ever is earlier

15. Number of chances for passing institutional or posting examination. No probationer will be allowed
to reappear in any institutional or positing examination except for the following reasons:a) If a probationer is prevented from appearing in any examination either because of his/ her
sickness or any other reason beyond his/ her control, he/ she may be allowed to appear in a special
examination within three months.
b) In case a probationer does not pass any institutional or posting examination in the first attempt,
he/ she may be allowed to sit for re-examination ion the papers in which he/ she has failed. But in
39

Guidelines for IRSMEProbationers, IRIMEE/ JMP


that case, the marks awarded in such re-examination shall not be taken into account in determining
the seniority (his/ her score in the original examination only will be counted)
10.1 The exemption in (b) above, will also apply to the probationers who have been permitted to
take special examination in the circumstances mentioned in (a) above.
10.2 If a probationer fails to pass examination in the second chance, (b) above, his/ her services are
likely to be terminated.
10.3 However, SC/ ST probationers may be given a third chance by the Ministry of Railways after
considering the merits of the case and after this they would also be dealt in the same manner as
other probationers.
16. Minimum percentage of pass marks in the Examinations prescribed after completion of institutional
training and posting examination.
The minimum marks to pass in examination after completion of institutional training (Foundation
course, Induction course, Phase I, Phase II etc.) and posting examination will be 60%in aggregate
as well as in each individual paper.
17. Guidelines for awarding of marks by Director/ Principal:
For award of marks under the column of Directors/ Principals assessment, the Director (of IRICN,
IRISET, IRIEEN, IRIMEE) and Principal (of Railway Staff College) through the Training Director of
probationers, will follow the following guidelines:12.1 General Performance:
Marks under the column will be awarded by the Training Director, based on the overall behaviors of
the probationers keeping in view:(i)
(ii)
(iii)
(iv)
(v)
(vi)

General Discipline
Participation in extra curricular activities during training.
Behavior with colleagues.
Mental awareness and alertness.
Willingness to share and shoulder higher responsibilities and
Attendance in Library.

12.2 Practical Training:


The Training Director will keep a watch on the progress of training being received by the
probationers in order to award marks against this column. He/ She will take the following steps:(a) Interview the probationers at frequent intervals regarding the progress made by them.
(b) Scrutinize at frequent intervals, the diaries and note-books kept and maintained by the
probationers regarding the details of their day-to-day activities.
(c) Carry out random inspection at the site of training.

40

Guidelines for IRSMEProbationers, IRIMEE/ JMP


(d) Obtain a feed back from officers under whom the probationers are undergoing practical
training , and
(e) Other steps as deemed appropriate.
18. Extension of probationary period:
The Ministry of Railways may, if it so deems fit in may case extend the period of probation for a
maximum period of one year. However, if during the period of probation, a probationers is placed
under suspension, pending investigation, enquiry or trial relating to a criminal charge sheet against
him/ her or pending disciplinary proceeding which are contemplated or started against him/ her, the
period of his probation may be extended for such periods as the Ministry of Railways may think fit in
the circumstances of the case.
19.Zonal Railways and training institutions are requested to take necessary steps to ensure the
implementation of the above instructions.
Please acknowledge.

DA: As above
(AMARNATH)
DIRECTOR(TRAINING)
RAILWAYBOARD

41

Guidelines for IRSMEProbationers, IRIMEE/ JMP

Maximum marks distribution during probationary training

200

42

280

350

Total maximum marks for


Proba-tionary Training

70

Total

Posting Exam

Total
400

Practical field
Training

200

Assessment by Director/
Controlling Officer

General
Performance

200

PHASE-II

150 300

Training in
Professional
Institutes

PHASE-I

Induction

150

Total

Foundation
Max
Marks

Training in
Railway College

Annex- A

1250

Guidelines for IRSMEProbationers, IRIMEE/ JMP

E. ITEMSOFGENERALINTEREST
1. Territorial Army
While you are serving on the Railways, you also have an opportunity to contribute to the
Defense of the country and help in times of civil disturbances that affect the Railways. You can
do this by becoming a member of the Railway Territorial Army. This is a Para-Military force
that draws men from the Railways, puts them in army uniform and trains them in the army
way of life for. One month every year. The Railway will release you for this on month. In
return, you can be called upon in the event of a war for working trains in border areas or even
in foreign territory. During peacetime disturbances such as strikes or bandhs also, you can be
called upon to help the Railway authorities. You will be given an army rank in the Territorial
Army commensurate with your Railway status.
2. Hostel

There are three hostels in IRIMEE

Yantrik Niwas:

Primarily for IRSME(P)s and posted officers trainees.

Gymkhana:

For Special class Apprentices and to accommodate


spill over from Yantrik Hostel.

Queens Road Hostel:

For Officers and supervisors in separate wings.

3. Recreation Facilities

Gymkhana has indoor and outdoor games facilities in addition to reading room, music room,
billiard room, hobby centre etc.

Yantrik Niwas has recreation room with TV, Table Tennis and other indoor games, a reading
lounge with magazines and news papers, gymnasium room and a dedicated computer room
with internet facility. For other games like badminton, billiards, swimming etc the facility
available at officers club may be utilized by the officers.

All residents of Yantrik Niwas are members of Yantrik Niwas Club on a nominal weekly
subscription as applicable time to time. The amount is used for consumables for recreational
facilities and for purchase of recreational & sports equipments etc.

Officers Club of Jamalpur: All trainee officers are automatically members of Officers Club,
which has games and swimming pool facilities in addition to weekly get together programme.

Golf Club: Jamalpur has a cheap and decent Golf Course, which can be made use by
Probationers.

43

Guidelines for IRSMEProbationers, IRIMEE/ JMP


4. Addresses of important Rest House of Indian Railways
1.

DLW

2.
3.

RDSO
ICF

4.

Chennai

5.

Chennai

6.

Waltair

7.

Kolkata

8.

Hyderabad

9.

Gorakhpur

10.

Guwahati

11.

Bangalore

12.
13.

RWF, Yalahanka
Bangalore Cantt

14.

Old Delhi
New Delhi
Sadar
Bazar, 6 rooms m- There is a big bldg, as we go along the track from
Delhi
N.Delhi to Old Delhi. This bldg. has guard running room and
A/ cs office. There is a narrow passage for this (ADM/ N.Rly)
Kashmiri Gate, Construction Rest House, CAO , N,Rly.
Delhi
Mumbai
For western railway. 1, imperial Mansion (Near Badhwa Park)
1, Caffe Parade, Bombay-2 for Central Railway Marana
Road, Probationers rest House, Mumbai

15.
16.
17.

Probationers Rest House, Opposite Technical Training School,


Varanasi
Probationers Rest House, RDSO, Lucknow
Probationers Hostel, ICF Colony, Perambur, Chennai,
Probationers Rest House, Egmore Rly Station
Constn. Rest House (Near Egmore Railway Station) Opposite
Hotel Peacock, Controlled by CAO (C)
Officers Rest House, Anna Sali (S.Rly.City Booking Office) near
LICBuilding
CRH (Constn.) adjacent to CAO Office (Near DRM Office
controlled by Secy. To CAO
Probationary Officers Rest House, 55 Church Road, Opp .
opply, Orthopedic Hospital, Howrah (No booking required,
Probationers Rest House, adjacent to Sanageeta Theatre,
Begam Path
Officers Rest House (Near Stadium) (Railway Colony)
Controlled by Secy. To GM.
Get down at Kamakhya Rly.Station. Bridge View Rest House,
behind RPFbarrack, Maligaon
Room No.23 and 24 at Station Building, controlled by SS/
Matron
P3robationers Rest House, RWFColony, Yalahanka
Construction Rest House, behind Rly.Station, controlled by
section officer
Probationers Hostel, near Division building

44

Guidelines for IRSMEProbationers, IRIMEE/ JMP


5. LIST OFOFFICERSREST HOUSEON INDIAN RAILWAYAT PLACESOFTOURIST INTEREST
PLACE
PATHALGAM
Srinagar
Shimla
Chandigarh
Mussoorie

NEAREST RLY. STATION/


DIVISION (DISTANCE)
JAMMUTAWAI (300 KM)/
Firozpur
-do-doChandigarh/ New Delhi
Dehradun/ Moradabad

Agra Cantt.
Agra Cantt/ Jhansi
Khajuraho Caves
Harpalpur/ Jhansi
Matharan
Matheran/ Bombay VT
Lonavala
Lonavala/ Bombay VT
Igatpur
Igatpur/ Bombay VT
Pune
Pune/ Bombay VT
Mahbeleshar
(only
Pune/ Bombay VT
during season)
Ajanta
Jalgaon/ Bhusavai
Ellora
Aurangabad/ SCR
Agra Fort
Agra Fort/ Kota
Agra Idgah
Agra Fort/ Kota
Bharatpur
Bharatpur/ Kota
Gholwad
Gholwad/ Bombay
Central (Near Bulsar)
Mt. Abu
Abu Road (20 KM) Ajmer
Jaipur
Darjeeling

Jainpur/ Jaipur

Karseong

Karseon/ Kathihar (Siligur) (50


kms)
Gauhati
NJP/ Khatihar
Kathgodam (28 kms)Izzat
Nagar
Dehradun (35 kms) Knurl
Vasco-de-Gama/ Hubli
Coonoor/ Palaghat (10 kms)
from Ooty
Trivandrum

Shillong
New Jalpaiguri
Nainital
Mussoorie
Vasco-de-Gama
Ootacommund (Ooty)
(Rest at Coonnoor)
Trivandrum

Darjeeling/ Kathihar (Siliguri)


(70 kms)

45

BOOKED BY
i) DGM Baroda House, NDLS
ii Protocol Officer, Rly. Board, New Delhi
-do-doDEN, Ambala Cantt.
i) DSE(E) Moradabad Divn.
ii) CPO (E.Rly)Fairlie Place, Kolkata
iii) DSE, Firozepur Divn.
iv) SSPathankot (N.Rly.)
i) Area Officer, Agra Cantt.
i) Sr. DEN/ Jhansi
i)Sr. DEN (SE)BBVT
-do-do-do-doI)SS/ Jalagaon
i)SS/ Aurangabad
i) SS/ Agra Fort
i) AEN/ Bharatpur
I) AEN/ Bharatpur
i) Sr.DEN (ii) Bombay Central
i) PA to CE/ W.Rly. CCG/ BB
ii)AEN Udampur at Rana Pratap Nagar Stn.
ZTSPrincipal, Udaipur
Se. DEN/ Jaipur
i) Secretary to GM/ Maligaon (Assam) NFR
ii) Secy. To GM/ Kolkata (ER)
iii) Secy. To GM/ Gorakhpur (NER)
Secy. To GM (Maligaon)/ NFR
i) Secy. To GM (Maligaon)/ NER
i) AAEN/ NJP(NFR)
ADGM/ NERly.HQ.Gorakhpur
Secy.to GM/ Gorakhpur
Sr.DEN/ SCR/ Hubli/ Karnataka
Sr.DEN-II/ Palghat (TN)
Sr.DEN/ Trivandrum (S.Rly.)

Guidelines for IRSMEProbationers, IRIMEE/ JMP

Kaanyakumari
Madurai

Kaanyakumari
/ Trivandrum

Ranchi

Madurai
Kaanyakumari
/ Trivandrum
Rameshwaram/ MaDURAI/
Mysore/ Mysore
Ranchi

Konarak Temple

Khurda Road/ Khurda Road

Puri
Ranchi (SER)Ranchi
Mussorie
(NR)Dehradun
Besides

Puri

Kodaikanal
Rameshwaram

i) Dy.CE.S.Rly. HQ Madras for Constr.


Rest House
ii) Sr. DEN/ SR/ Maduari
Sr. DEN/ SR/ Maduari
Sr. DEN/ SR/ Maduari
Sr.DEN/ SR/ Mysore
CPO/ SER/ Garden Reach/ Kolkata
i) Dy.COS/ SER/
Garden Reach/ Kolkata
ii) DEN/ Khurda Road,SER/ Garden Reach/
Kolkata
SDGM/ SER/ Garden Reach/ Kolkata
CPO/ HQ/ ER/ KKK
-do-

1. Accommodation is available for probationers at all Railway HQ either at


Main Station or on Railway Officers Rest House
2. At Lucknow, RDSO Rest House and Mathura, Allahabad. Railway
Electrification (RE) Rest House Exist
Following places have subordinate holiday homes
1. Bandra (WR) 2. Badrinath (ER) 3. Borog (NR) 4. Lonavala (CR) 5.
Matheran (CR) 6. Darjeeling (NFR) 7. Simla (NR) 8. Pahalgam (NR) 9.
Srinagar (NR) 10. Udaipur (W.R) 11. Madurai (SR) 12. Mysore (SR) 13. Goa
at Margaon (SCR) 14. Kathgodam, Nainital (NER) 15. Coonoor (Ooty) (SR)
16. Pune
(SER) 17. Ranchi (SER)

46

Guidelines for IRSMEProbationers, IRIMEE/ JMP


6. FACULTYLIST & TELEPHONEDIRECTORYOFIRIMEE/ JMP
IRIMEEFAXNo.: 06344 - 243293
NAME(S/ SHRI)

DESIGN

BRaikwar
D.Bhattacharjee
Rajendra Pal Singh
H KRaghu
Tanmay Mehta
Samir Lohani
Swapan Kr. Sen

Director
PA / DIR
Dean (RST)
Sr.Prof (DT)
Sr. Prof (RST)
Prof. (WMT)
Prof. (DSL)
Prof. (Met)
Prof. (RST)
Asst.Prof (Dsl)
Asst.Prof (C&W)
Asst.Prof (IT/ Elect.)
Asst. Prof. (Proj)
Lect.(Met)
Lect.(DSL-I)
Lect.( Dsl-II)
Lect. (Mech)
Lect (C&W)
TV Programmer
CI (Met)
CI (Mech)
CI (Dsl / Elect)
CI (C&W)
O/ SIRIMEE
Sr.Lib
Warden / QRH
Janiter/ YN
HS/ SGH
PRS

Ashish KKulhada
G.N.Singh
Sreeram Singh
Arbind Kumar
Utkarsh
S.L.Pandit
Sudarshan Pandey
Pankaj Kumar
Abhyuday
Sanjay Kumar
Girish Kr. Verma
Arvind Lal
Subhas Ch. Patra
Sanjay Kr. Sinha
Rajeev Roushan
Vijay Mandal
Debashis Ghosh
S. K. Chaurasia
Arvind Kr Singh
Gautam Bagchi
Arbind Tiwary

RLY
OFF
24500
24500
24502
24506
24502
24508
24510
24518
24516
24520
24526
24534
24532
24524
24530
24536
24522
24540
24542
24544
24549
24548
24546
24539

RES
24501
24505
24507
24509
24511
24519
24517
24367
24385
24535
24533
24537
24529
24547
-

P&T
OFF
243184
243184
243294
241747
241779
241750
241748
241764
241749
241765
242370
241746
-

Important email addresses:


BRaikwar
Rajendra Pal Singh
H KRaghu
Tanmay Mehta
Samir Lohani
Swapan Kr. Sen
Gautam Chowdhury
Ashish KKulhada
Utkarsh

Director
Sr. Prof (WMT)
Sr.Prof (DT)
Sr. Prof (RST)
Prof. (WMT)
Prof. (MIS)
Prof. (DSL)
Prof. (E& Met)
Prof. (RST)
Asst.Prof (Project)

diririmee@gmail.com
spwmt.irimee@gmail.com
spdt. irimee@gmail.com
sprst. irimee@gmail.com
pwmt. irimee@gmail.com
pmis. irimee@gmail.com
pdt. irimee@gmail.com
pem. irimee@gmail.com
prstirimee@gmail.com
works.irimee@gmail.com

47

RES
241793
240521
243292
241754
241790
241756
241757
243131
240024
242426
244240
-

MOBILE
9771462400
9771462419
9771462402
9771462408
9771462403
9771462406
9771462407
9771462404
9771462409
9771462410
9771462411
9771462412
9771462405
9771462413
9771462420
9771462415
9771462414
9771462416
9852532081
9771462418
9771462430
9771462421
9431236812
9955610432
9905024979
9771462417
-

Guidelines for IRSMEProbationers, IRIMEE/ JMP

48

Guidelines for IRSMEProbationers, IRIMEE/ JMP


NOTE
No. IMEE/ Prob

Sub:

Dated: 07.09.09

Dress code for IRSMEProbationers

IRSMEProbationers must be advised to follow the dress code as mentioned below: Tie : IRSME(available at IRIMEEon payment basis)
Pant: Silver Grey
Shirt: White

The above uniform shall be used by the probationers during their training at Headquarters
and all other CTIs of Indian Railways.

Wearing is compulsory at IRIMEE for all officers. When probationer joins at IRIMEE, they
must be advised of the dress code. They must also be advised to equip themselves within
15 days from the date of their joining.

The above must also be included in the requirements of a probationer.

Sr.Pof. (RST)

P(RST) : For Probationers


P(Dsl) : For all officers

49

Guidelines for IRSMEProbationers, IRIMEE/ JMP

GUI DEL I NES FOR I RSM E PROBATI ONERS

VOL II (FIELD TRAINING)

50

Guidelines for IRSMEProbationers, IRIMEE/ JMP

INDEX: Volume II (Field Training)

SN

Item

Page no

GENERAL DIRECTIONS FOR FIELD TRAINING

45

BROAD GUIDE LINES FOR FIELD TRAINING

46

TRAINING AT RDSO

47

TRAINING AT DLW / VARANASI

48

TRAINING AT DMW PATIALA

50

TRAINING AT DIESEL SHED

50

TRAINING AT DIESEL P.O.H WORKSHOP

52

TRAINING AT RCF/KAPURTHALA

52

TRAINING AT ICF / CHENNAI

53

10

TRAINING AT RWF/ YALHANKA ( BANGALORE)

58

11

TRAINING AT CARRIAGE POH SHOP

59

12

TRAINING AT COACHING DEPOT/DIVISION WORKING

59

13

TRAINING AT WAGON POH SHOP

62

14

TRAINING AT ROH DEPOT OF BOXN WAGON

63

15

TRAINING AT GOODS YARD

64

16

CHECK LIST FOR DIVISIONAL AND WORKSHOP PRACTICAL


TRAINING FOR IRSME PROBATIONARY OFFICERS

67

17

GUIDE LINES FOR ZONAL TRAINING OF IRSME PROBATIONER

70

18

LIST OF PROJECTS

72

19

QUESTION BANK

85

20

LIST OF CODES, MANUALS AND OTHER PUBLICATIONS

91

21

CHECK LIST FOR INSPECTION (RAILWAY BOARD

93

22

CONTACT OFFICIALS FOR FIELD TRAINING

93

23

SYLLABUS OF IRIMEE COURSES

94

51

Guidelines for IRSMEProbationers, IRIMEE/ JMP

GENERAL DIRECTIONS FOR FIELD TRAINING

1.

Report to the head of the unit and meet the training in_charge and other concerned officials on
the first day.

After reporting, probationers should inform about their reporting to the training coordinator at
IRIMEE by phone.

Appreciate and become aware of organization, activities, products and technologies of the
unit.

The unit wise guidelines given can be modified by unit in which training is being imparted, to
allow inclusion of other important areas considered relevant and exclusion of areas that may
have become redundant.

Nominated local officer or supervisor should take around the premises on first day and will
explain important areas of each sub unit.

Do maximum possible foot plating during divisional/ Zonal attachments. The order should be
at least 4 trips.

Diaries should be meticulously maintained daily, based on observations made, and,


periodically systematized in form of summaries/gist in organized manner. This will greatly
assist in retention of knowledge gained, apart from being a mandatory requirement of training.
Signature of the unit in_charge or training in_charge should also be obtained on the
diaries.

Most importantly, remember that you must gain knowledge for your own development and not
for anybody else. Your reception and retention abilities are about the best at this stage in life.
As you rise in the hierarchy, owing to continuous increase in managerial responsibilities, you
will find lesser time and opportunity for acquiring basic technical knowledge pertaining to your
work, while the basis of sound managerial decision making is depth of technical knowledge.

Proper relieving letter should be brought from each of the field unit in the format given
below. The relieving letter should be submitted to the section clerk at IRIMEE so that your
attendance may be claimed for salary payment.

Name of Field Unit/ Organization: .


Training From: ..
SN

Name of Probationer

To: . (Date)
Particulars of Leave/

Particulars of the Pass

Absenteeism

taken

Signature

52

Guidelines for IRSMEProbationers, IRIMEE/ JMP

If any Railway accident occurs nearby to the place of training, after taking due permission

from the Unit In_charge/ Training In_charge, probationers must witness the role of various
department, specially that of mechanical department at the accident site. (Call IRIMEE
officials, if required, for any assistance for getting relieved to accident site.)
The probationers have to select one project and during their field visits and institutional

course they should strive to collect relevant technical and other information. Topic of the
project should be decided in consultation with the faculty in_charge at IRIMEE with in 90
days of joining the probationary training.

2.

BROAD GUIDE LINES FOR FIELD TRAINING

During each field training, the probationers are required to proceed from Broad aspects to
minor details as given below:-

2.1

Organization, out turn, lay out, flow of units and materials.

2.2

Broad stages and processes of production/processes.

2.3

Detail of each stage and process

2.4

Important parameters of each process which affects quality.

2.5

Critical look at Actual practices vis--vis Recommended practices (Manual)

2.6

Cycle time stage wise.

2.7

Sketches and drawing in own hand for better understanding of assembly, component,
and processes.

2.8

Failure data analysis and remedial actions.

2.9

Reliability increasing measures, new / future developments, modernization, Expansion

and critical issues etc.

53

Guidelines for IRSMEProbationers, IRIMEE/ JMP


3.

TRAINING AT RDSO
Directorate

Topics to be covered
1.

Role of Mechanicals Directorate in RDSO.

2.

New Design of locomotive and their broad features

3.

Adhesion, Load factor and haulage calculation.

4. Bogie suspension characteristics ride quality & ride comfort. Speed


certificate & CTRS sanction for rolling stock.
Motive Power

5. Important design feature of 140-T crane including stability, hydraulic rerailing equipment.

& Engine
Development

6.

Diesel Multiple Units & self-propelled vehicle.

Directorate

7.

Salient features of different types of brake system, EBD calculations.

8.

Automatic switching of ON of flasher light.

9.

Composition brake blocks

10. Up gradation of power pack and its testing.


11. Important features for achieving fuel efficiency
12. Emission norms and pollution control.
13. VCD, ACD and other safety feature.
1. Fundamentals of designs salient features of various designs of
coaching stock and EMUs and DEMUs.
2.

Air brake system on passenger coaches.

3.

Composition brake blocks

4. Evolution of coaching stock design for improving the reliability,


maintainability and safety.
5. Design standardization of wheels, axles, roller bearings, drafts and
buffing gears.
Carriage

6.

Carriage maintenance group meeting and decision taken.

Directorate

7.

Limitations of moving gauge and axle load for coaching stock.

8. New trends in the design of coaching stock and EMU/DEMU with


respect to higher speed, safety, increased comforts, reduced energy
consumption and improved passenger amenities.
9.

Key features of LHB design, maintenance manual of LHB coaches.

10. Air suspension arrangement for coaching stock.


11. CBC for coaching stock.
12. Crash worthy ness of coaches.
13. Newer types of toilets for the coaches.

54

Guidelines for IRSMEProbationers, IRIMEE/ JMP

1. Role of standards and material specifications applicable to Indian


Railways.
2. Introduction to welding technology various welding methods,
characteristics & classification of electrodes.
3. Introduction to destructive & non-destructive testing of materials and
welded joints as applied on Indiana Railways.

M&C Testing
Directorate

4. Methodology of metallurgical investigation into failure of critical


components.
5.

General characteristics of lubricants.

6. General characteristics & evaluation of paints & coating, corrosion


preventive methods.
7. Criteria followed for passing rolling stock, general idea of test schemes
for oscillation, performances & rating trials.
8.Familiarity

with

vehicle

characterization,

fatigue

and

brake

dynamometer test.
1. Broad considerations in design of conventional wagon, moving
dimensions and their influence in wagon design.
2.

Functions of various bogie components.

3.

Appreciation of design of components like axles, wheels and bearing.

4.

Different type of couples under on I.R.

5. Corrosion medeling of critical wagon components and analysis of the


design.
6. Inspection of wagons and sub-assembly, methods of various approvals
Wagon
Directorate

etc.
7. Different stages of wagon development and adoption starting from
requirement stage to final validity and adoption stage.
8. Various types of national and international specifications which are
required to be referred for designing activity e.g. IS, IRS, AAAR, UIC,
ASTM etc.
9. Modern concepts in bogie designing e.g. cross braced bogies/scheffel
bogie etc.
10. TLD and other track parameters affecting design of wagon.
11. New development in freight stock.

55

Guidelines for IRSMEProbationers, IRIMEE/ JMP

56

Guidelines for IRSMEProbationers, IRIMEE/ JMP


4.

TRAINING AT DLW / VARANASI

4.1

Organization and functioning of DLW.

4.2

Study and understand flow chart of engine assembly.

4.3

System of work order, rolling stock program and latest product mix for manufacturing of various
types of locomotives.

4.4

Welder qualification at TTS, DLW.

4.5

Procedure for bulk import indent of diesel spares.

4.6

Special features of new locomotives Viz.: WDP2, WDG2 and WDG4 locomotives.

4.7

Study of various processes of manufacturing through following shops:-

4.7.1

Light Machine Shop:


a)

Important out turn/activity cylinder head, cam shaft, con. Rod, gears, statistical quality
control of the processes involved.

b)

Important machines, cylinder head boring machine, gear hobbing machine, gear shaving
machine, cam milling machine, cam grinding machine etc.

4.7.2

Heavy Weld Shop:


a)

Important procedure: Submerged arc welding (Internal and external), 8 torch CNC flame
cutting machine.

b)
4.7.3

Important out turn: Cylinder block, Main base of engine, turbo support.

Heavy Machine Shop:


a)

Important out turn : Cylinder block, main base & turbo support

b)

Important machine: Horizontal line boring machine (for crank shaft and camshaft boring in
cylinder block), special purpose angular boring machine (for middle and trop deck boring),
serration milling machine, CNC end drill.

4.7.4.

CNC & Rotor Shop:


a)

Important machine: CNCchucker and bar feeder, horizontal machine centre.

b)

Important out turn: Fuel pump support, main casing turbo super charger, intermediate
casing BG turbo super charger.

4.7.5

Sub Assembly Shop:


a)

4.7.6

Activity: Assembly of cylinder head, water pump, fuel oil pump, OSTA etc.

Chrome Plating Shop:


a)

Out turn: Chrome plated cylinder liners.

b)

Important machaine/procedures: Plating bath, etching baths, honing mach8ine, surface

finish RMS measuring equipment.

57

Guidelines for IRSMEProbationers, IRIMEE/ JMP


4.7.7.

Engine Erection: Engine Assembly

4.7.8.

Engine Test Shop : Load Box Test

4.7.9.

Loco Frame Shop:


Important activity: Under frame fabrication
Important machine: Fabrication jigs, shearing bending and flame cutting machines.

4.7.10

Traction Assembly:
Assembly of traction motors: Control panel and control stand of the locomotives.

4.7.11

Loco assembly Shop: Assembly of the locomotives.

4.7.12

Loco Training Shop:


Power Pack with traction generator and control equipment testing pneumatic testing.

4.7.13

Loco Paint Shop.

4.7.14

Pre departure Inspection:


Understanding of various inspection checklists.

4.7.15

Recent development in diesel locomotives.

5.

TRAINING AT DMW PATIALA


5.1

Organization and layout

5.2

Out turn of DMW as a whole and of important shops like T.M.Shop, Cylinder Plating
Shop, and Carbon Brush Shop.

5.3

Rewinding of T.M.Armatures.

5.4

Reconditioning of Engine Blocks

5.5

Chrome plating of cylinder liners.

5.6

Procedure and steps of rebuilding

5.7

Important assemblies and components replaced during rebuilding

5.8

Important modifications during rebuilding (with special emphasis of fuel efficient kit)

5.9

System of warranty of locomotive and components

5.10

Important Diesel Components manufactured for all Indian Railways and procedure of
manufacturing.

5.11

Carbon Brush Manufacturing: Important characteristics of Carbon Brush material.

5.12

Electronics Lab: Maintenance of CNCmachines.

5.13

Rail cum Road vehicle.

58

Guidelines for IRSMEProbationers, IRIMEE/ JMP

6.

TRAINING AT DIESEL SHED


6.1

STUDY FOLLOWING:
o

Organization Chart

Shed Layout &

Power Plan, Outage and other Shed Performance Characteristics.

Study schedule forms for Minor & Medium schedules (Mech. & Elect.)

o Study the History Cards of locomotives and method of forecasting and planning their
schedules.

6.2

OBSERVE FOLLONG:
o

Yearly schedule details of activities, their PERT chart and execution.

o Attend one shift each with shift in charge (M), shift in charge (E) and observe their
working.
o

Observe load box test of loco after major schedule and study the records, plot control
chart for some important characteristics.

Study and observe the complete failure investigation of a locomotive.

o Study the availability of staff, infrastructure, and M&P items in the shed and their
adequacy.
o Study the system of receipt & issue of fuel oil and the details of various monthly
statements sent to HQ.
o

Study the calculation of S.F.C (Loco wise & service wise) and shed consumption.

Study schedule forms for various minor & medium schedules (Mech. & Elect.)

Attend various maintenance section (Mech. & Elect.) Study M.I.s for the section and
observe details of various checks and measurements.

Study the system of drawal of items from Stores and their accountal.

Study the systems of procurement of various types of items (Imprest, stock & Non-stock).

Foot plate & locomotive out from shed and observe the working of crew.

6.3

SPECIAL ATTENTION

Facilities Infrastructure, staff, training and M&P items available and required,

Technical Cell History cards, failure investigation, schedule planning, performance


indices, technical instructions.

Spares Cell System of procurement of (a) imprest items, (b) stock items & (c) Nonstock items. System of drawal of items from Stores and their accountlal.

Fuel & Statistical Cell System of receipt and issue of fuel oil, calculation of S.F.C (Loco
wise & service wise) and shed consumption, details of monthly statements.

59

Guidelines for IRSMEProbationers, IRIMEE/ JMP

TRAINING AT DIESEL P.O.H WORKSHOP

7.

a) Organization lay out of the shop and out turn.


b) Facilities required of M&P etc.
c) Unit spares requirement criteria and actual available
d) Various maintenance sections (Mech. & Elect.) Study M.I.s for the Section and observe
details of various checks and measurements.
e) Analysis critically at least three assembly overhauling (actual vs ideal as given in manual)
and prepare report after discussion with officer in charge of the section.
f)

Study various N.D.T. Methods in use, and other lab activities like USD of Axles.

g) Observe Load Box Test and Study the records.


h) Study the system of Customer Service (feed back of failure of locomotive within one year
of POH)
i)

Accompany a loco on field trial after POH.

j) TRAINING AT RCF/KAPURTHALA
While visiting RCF/Kapurthala, following items may be specifically looked into:
1.

The Production Flow Plant lay out, various stages of manufacturing of the coaches.

2.

Important manufacturing techniques and Machinary & Plant:

a)

Production Machines/Shops
Under water plasma cutting machines,
Cold Roll forming and cut to length machines.
Laser FMC (Flexible Machine Centre)
Plasma Punch Press
CNC Pipe Bending Machines
Roll bending and 1000 ton press
3-D Measuring Machine
Automated Painting system for shell painting.

b)

Material Handling Equipment:


CNC Auto-stacker system
Remote Control Overhead cranes
Rail-Cum Road Vehicle

60

Guidelines for IRSMEProbationers, IRIMEE/ JMP


Rollbaw Vacuum Shop cleaning with scrubbers
Palletisations
Traversor for changing the line

c) Important Jigs like Shell Assembly, Side Wall and Roof

3)

GAIT A centralized computer centre having a Main Frame & a large no. of terminals.

The software packages under use like Plant Maintenance, Personnel, and STORM Stores/
Material Management, Medical and Finance management
Design Office, CAD/CAM work centres and other facilities
Important Soft wares.
Use of FEM analysis for developing new designs.

4)

Special features shed design and construction:

Double roofing with aluminum

Lighting system

Ventilation and heating system

5)

Certification of ISO 9001 in Bogie Shop

6)

Energy conservation:

Street lightning with timers

Solar water heaters

7)

Visit to Staff Canteen & Training School

8)

Design, fabrication, furnishing of LHB coaches, FIAT bogies

61

Guidelines for IRSMEProbationers, IRIMEE/ JMP

8.

TRAINING AT ICF / CHENNAI


1. ORGANISATION & LAYOUT
2. DESIGNS
a) Study of various aspects of Railway passenger coach designs conventional and special
stock salient features of integral design.
b) Design of metro coaches.
c) Study of design aspects of air brakes in EMU, etc.
3.

SHEET METAL SHOP


a) Study of 1000 T and 800 T Hyd presses. With special emphasis on CNC and Plasma
Turret Press.
b) Sheering machine with special emphasis on CNC shearing centre.
c) Butt seam welding machines
d) Spot welding machine
e) Profile bearing machines
f) Notching machines
g) Submerged are welding machines
i) Side wall assembly
ii) End wall assembly
iii) Hot phosphating and cold phosphating procedures

4.

1.
2.
3.
4.

Roof assembly jig


Under frame assembly jig
Body shell assembly jig and universal jig for body
Bogie testing machines
a.
b.
c.
d.

Roof assembly and welding sequence


Under frame assy. And welding seq.
Camber setting
Assembly of under frame, side wall and wall and roof in jig stage and welding
sequence.
e. Bogie frame, assy and welding sequence
f. Bogie frame straightening
g. Roller bearing assembly
h. Bogie assembly & air spring
i. Bogie testing and final inspection
j. Stainless steel welding of trough floor
5.

Study of following:
1.

Grit blasting plant

2.

Air less spray painting equipment

a.

Surface preparation equipment

b.

Sequence of painting operations

c.

Wheeling of coaches

62

Guidelines for IRSMEProbationers, IRIMEE/ JMP


d.
5.

SPRING MANUFACTURING
1.
2.
3.

6.

Cam and camless auto lathe


Bekoma boring M/c.
Copy turning lathes

MILWRIGHGT
1.
2.
3.

9.

Agro Shield Gas Welding Technique


Photo mat gas cutting machines
CO2 welding plants
CO2 welding techniques in comparison with other welding methods
Agro shield gas techniques & advantages.

COMPONENT SHOP
1.
2.
3.

8.

Bar peeling machines


Bar straightening machines
Spring coiling machines
Spring manufacture (various sequences)
a.
Spring testing
b.
Heat treatment of springs
c.

NEW BOGIE SHOP


1.
2.
3.
4.
5.

7.

Final assy. And Air brake test

Gear hobbing machines


Gear shaping machines
EOT Cranes
Preventive maintenance and lubricating procedures.
a.
Procedure for procurement of plant and machinery
b.
Procedure for condemnation and replacement
c.

TOOL ROOM
1.
2.

Jig boring Machine


Die sinking machine
Maintenance of 1000 T and 800 T press tools
a.
Maintenance of pneumatic tool
b.
Tool grinding and small tool maintenance
c.
Manufacture of press tools, jigs and fixtures
d.
Periodic maintenance of jigs and fixtures.
e.

63

Guidelines for IRSMEProbationers, IRIMEE/ JMP


10.

INSPECTION
Study of various standard inspection procedures:

11.

1.

Detail stage

2.

Sub-assy. Stage

3.

Major assy. Stage

4.

Installation stage

5.

Final inspection

6.

Issue of rolling stock certificates

FURNISHING
Study of stage wise assembly of interior furnishing:

a)

Preparation and laying of variculate, decolite mixing and coach flooring

b)

Roofing, roof wiring

c)

Interior paneling for sides and roof

d)

Plumbing and lavatory fittings.

e)

Interior wiring, fitting of seats and berths, assembly of vestibule arrangements,


fitting of windows etc.

Study of

12.

13.

a)

Wood working techniques

b)

Seasoning of timber

c)

Impregnation treatment

d)

Various paneling materials

e)

Manufacture of items with F.R.P.

Study of
a)

Window assy.

b)

Vestibile assy.

c)

Manufacture of aluminium water tank.

General study of trimming process.

64

Guidelines for IRSMEProbationers, IRIMEE/ JMP


14.

Study of air brake arrangement for EMU, metro and Rajdhani coaches.

15.

Study of electroplating and anodizing process

16.

Planning Department
Study of:

17.

a)

Work order system

b)

Planning for production

c)

Preparation of design and drawings for new builds

d)

Process Planning

e)

Maintenance of computer master files.

f)

Release of production documents

g)

Accountal of shop manufactured items.

Production Control Department


Study of functioning of

18.

a)

Centralized PCD

b)

Shop PCD

Data Centre: Study of application of computer in production planning, inventory control,


preparation of wage bills, continuous monitoring of production and stores position.

19.

C.M.T. DEPARTMENT
a)
b)

Non destructive and destructive testing of weld specimens.


Gamma rays, magnaflux, X-ray, Ultrasonic testing procedures and
applications.

c)

Testing of paints, rubber items, steel and lubricants

d)

Testing of timber, paneling materials, other furnishing materials.

e)

Testing of electro plates items.

65

Guidelines for IRSMEProbationers, IRIMEE/ JMP


RECOMMENDED READINGS AT ICF

Prevention of corrosion on ICF Coaches

Advisory consultancy on control and Prevention of corrosion of interior Parts of integral coaches

By Central Electro Chemical Research Institute, Karaikudi

Unified Maintenance Manual for Coach Stock

Design Manufacture of Light-weight Coaches by K.Swarup

One-man Committee Report on Roller Bearing applied to ICF Coaching Stock

By Sri K.Raman, CME/SR

Instruction for inspection and maintenance Of Direct-mounted Roller bearing axle boxes

Of BG/CF Bogies

Summary of recommendation of Commissioner Of Railway Safety for prevention of fires on EMU


Stock

Latest trend in Coach Design to prevent Corrosion

Remedial Measures incorporated in ICF Coaches In design, material and processing to combat
Corrosion

Starting and Rolling Resistance of I.C.D.F.. All coil coaches

Some investigation into the riding Qualities of all-coil ICF and MAN-HAL Bogies

Specification for Air Brake for passenger Stock of Indian Railways

Disc-brake specification for disc-brake Equipment for EMU

A brief report on corrosion of ICF Coaches

66

Guidelines for IRSMEProbationers, IRIMEE/ JMP

9.

TRAINING AT RWF/ YALHANKA ( BANGALORE)


1.

2.

3.

AXLE SHOP
a)

Forging Process

b)

Heat Treatment

c)

Quality Control

WHEEL SHOP
a)

Features of Pressure Pouring

b)

Casting

c)

Quality Control

d)

Environment aspects and impact

CMT
a)

4.

10.

Destructive and non-destructive attesting methods of wheel and axles

AQUANTANCE OF ISO 9000, ISO 14000.

TRAINING AT CARRIAGE POH SHOP

1.

Organisational Structure & Layout

2.

Probationers have to go through Carriage Manual and prepare correct procedure, lay
out, flow of material vis--vis actual practices of the sheds. Reasons for deviation and
constraints.

3.

Wheel Shop: Process of wheel assembly, Dis-assembly, wheel press and other
equipment.

4.

Roller Bearing Section: Process for Dismounting, Cleaning, Inspection, Rejection and
Mounting.

67

Guidelines for IRSMEProbationers, IRIMEE/ JMP


5.

Bogie Section: Trammeling of Bogie and Dash pot and rectification.

6.

CBC and Draft Gear Section.

7.

Air and vacuum brake Section: Specially D.V.overhaul, system of checking of alarm chain
pull and brake rigging pay in Pay out of SAB.

8.

Coach Body Repair Section: Corrosion prone areas and its repair, overhead tank
overhauling, roof testing, cleaning and paint schedule of coach.

9.

Furnishing Section: Latest upgraded material, Crashworthy features, Use of compreg for
coach flooring, FRP windows etc.

10.

Misc: Heat Treatment of Hook, Draw Bar, Springs, Screw Coupling etc. NTXR passing,
UIC Vestibule.

11.

TRAINING AT COACHING DEPOT/DIVISION WORKING

A.

Understand
i)

Organization structure of Mechanical Department of the division.

ii)

Spread of division indicating C&W, loco facility and important features of the
particular division.

iii)

Contents of Sr.DMEs morning position, Ineffective etc

iv)

Analysis of loss of punctuality of mail and express train.

v)

Pit occupation chart

vi)

Lay out of coaching maintenance yard.

vii)

Lay out of sick line.

viii)

Procedure of sending coaches for POH.

ix)

Examination of date and sick marking of coaches.

x)

Maintenance of distributor valve

xi)

Maintenance of SAB brake regulator.

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xii)

Maintenance of brake gear

xiii)

Testing of air brake system

xiv)

Testing vacuum brake system.

xv)

Distribution of staff in sick line.

xvi)

Function of batch in maintenance yard.

xvii)

Replacement of primary spring.

xviii)

Replacement of secondary spring.

xix)

Foot plate inspection.

xx)

Plants and equipment in maintenance yard and sick line, Infrastructure facilities.

xxi)

Schedule maintenance of coaches.

xxii)

Cleaning agents used in washing line.

xxiii)

Provision of ART.

xxiv)

Analysis of enroute detachments.

xxv)

Derailment enquiry.

xxvi)

Corrosion prone area of coaches.

xxvii)

Marshalling in a rake for 110V and 24V coaches.

xxviii)

Rake links.

xxix)

Study the system for maintenance of coach history cards and forecast of
Maintenance.

B.

Do yourself
1.

Replace MU washer

2.

Connect & disconnect BP air hose.

3.

Replace brake block.

4.

Set A dimension.

5.

Isolate DV

6.

Carry out rolling in inspection of a passenger train followed by a detailed inspection of


the rake at the washing lines. Attach a detailed report of your observations covering the
coach interior furnishing rooms and lavatories, lights and fans on the superstructure and
wheels roller bearings, springs, brake gear, and draw and buffing gear on the under gear,
attach report).

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7.

Examine a passenger train rake before issue of BPC. Note the action taken to bring the
brake power up to 100% covering the following, date, location, rake no, train no, rake
link, no of cyl., overdue no. of cyl., defective, repairs done, brake power.

8.

Associate and supervise complete washing and cleaning of a rake both externally and
internally at the washing lines including toilets.

Determine and personally check

efficiency of on-train safaiwala operation.


9.

Associate and supervise complete pit line examination of a passenger rake along with
the maintenance supervisor. Do you feel that the time, space, light, hand tools and other
facilities are adequate to ensure safety and passenger amenities? Do you feel that work
is going on all the time when a rake is on the pit-cum-washing lines? Determine whether
maintenance of any rake is done on a non-pit line such as platform line or yard line. Can
it be avoided?

10.

Study the rake links for passenger trains originating on your railway and work out the
average kilometer earning for each link taking into account the spare stock. Suggest
revised rake links to improve the utilization without affecting maintenance.

11.

Study the system of booking a due POH coach to the assigned workshop. Work out
average time the coach actually remains ineffective on this account, the brake-up of
the ineffective time and your views regarding reducing the same. What precautions are
being taken to avoid thefts during transit and whether any cannibalization is taking place
and if so why? Determine extent of over-due POH running can be avoided? (Attach
sheets).

12.

What is the allotment of spare stock to your Division? What system exists for you to
ensure that stock belonging to your division and to your railway is with you and that the
other division/railways coaches are returned back to them? Are there any cases of under
load running on your division due to non-returning of coaches? What percentage of
coaches in use on the division is over aged? Can their use be avoided?

13.

Go through carefully the list of vital and safety spares required or coaching maintenance,
their sources of supply and your system to ensure adequate stock. Carry out a similar
exercise for passenger amenity fittings.
budgetary provision for maintenance?

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14.

Accompany (with permission) your Sr.DME during a routine inspection of coaching


pitline, sick line or washing line.

15.

Study the daily ineffective position of coaching stock and attach a report with your
suggestions for bringing this down.

C.

Prepare Report
i)

Summarize loss of punctuality of mail & express train for the last 6 months. Suggest
methods to reduce loss of punctually.

ii)

Prepare report or overdue POH coaches of or coaching depot. Suggest methods to


reduce over due coaches in trains services.

iii)

Prepare sick making of coaches for the last 6 months. Make parches paretos analysis
and suggest methods to reduce coach in effectiveness.

iv)

Prepare repot of sick making of coaches within 100 days of POH. Suggest to improve
such incidents.

v)

Prepare repot on major plants and equipment of the coaching depot and high light
maintenance practice adopted and suggest any improvement on present method of
maintenance practice.

vi)

Prepare report on critical items of the coaching depot.

Suggest method to improve

problem of : Stock Out.


vii)

Prepare a chart for the occupation of washing and pit lines.

viii) Attach a complete report on activities undertaken in your coaching sick line under
different headings.
ix)

Write a failure report and your own analysis for two coaching stock failures resulting in
detention and/or detachments enroute. (Attach sheets).

12.

TRAINING AT WAGON POH SHOP


GENERAL
1.

Preparation of Inspection Sheet.

2.

Study of incentive scheme with special emphasis on manpower planning in


relation to revised a allowed time of various operation.

3.

Study of ISO-9000 areas like CTRB, SAB Brake Regulator & Air brake
maintenance.

4.

Method of receiving wagons for POH inside Workshop.

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WAGON
1.

Type of wagons a particular workshop handling

2.

Target of the workshop.

3.

Man hours required type wise

4.

POH cycle & wheel flow cycle

5.

Infrastructure available

6.

Safety involved with cleaning of tank wagons, testing & adjustment of discharge
valve and security fitting of safety valve

7.

8.

Bogie repair
-

UIC

CASNUB

Air brake equipments overhauling with emphasis on distributor valve and SAB
brake regulator

9.

Overhauling of vacuum cylinder and draft gear.

10.

Unit exchange practice

11.

Reprofelling of wheel and reaxling/rediscing of wheel set.

12.

Paint schedules

13.

Ultrasonic testing of axle and testing of springs

14.

Neutral examination

REPORT
1. Make a report showing the actual POH cycle of any air braked wagon POHed at the
shop during your visit.
2.

Make a report describing in detail on reaxling/rediscing of wheel sets iin the workshop
you visited.

3.

13.

Prepare a duplicate inspection sheet of any wagon and make network for POH cycle.

TRAINING AT ROH DEPOT OF BOXN WAGON


1.

Observe lifting of body

2.

Observe stripping of bogie component

3.

Observe checking of frame alignment

4.

Observe repair of bogie and its re-assembly

5.

Observe maintenance of distributor valve

6.

Observe maintenance of SAB brake regulator

7.

Observe air brake testing using SWTR

8.

Study interception of BOXN WAGON for ROH

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9.

Study interaction with neutral control office

10. Observe replacement of draft gear


11. Observe replacement of CTRB
12. Observe in-situ injection of CTRB
13. Observe manual adjustment of brake rigging
14. Study corrosion repair

Do it yourself
i)

Replace MU washer

ii)

Isolate DV

iii) Perform take up/pay out test


iv) Connect Air HCl

14.

TRAINING AT GOODS YARD

1.

Examine one originating, one terminating and one by-pass goods train in each of the shifts from
the stage of receipt of train examination memo from the yard master till the issue of BPC or
release memo. Write your observations about time taken, defects noticed, inadequacy of tools,
light, C&W duplicates and obstructions due to unclean yards with date, yard, shift, name of TXR,
train to event times etc. (attach sheets)

2.

Observe the functioning of NTXR flying squad if provided on your division and follow up the report
of NTXR for its implementation.

3.

Deal with a clearance of ODC consignment fully and write a two page report. How important it is
for a heavy consignment to be centrally loaded and why?

How should shifting of a heavy

consignment during run be prevented? (Attach sheets).


4.

What are the pros and cons for a train examination being conducted on an originating train or a
terminating

train? What system is being followed on your division? How is it related to the

yard operations?

5.

Observe marshalling of two train loads on hump yard, one from the hump cabin and one along
with the staff. Write a report on the facilities provided, facilities used, humping speeds and
impact speeds of the wagons. Can you quantify the damages to the wagon stock on account of
uncontrolled and rough shunting? Examine a load formed after hump marshalling and ready to
leave and indicate the percentages of screw coupling on four wheeler stock not found adequately
tightened. What are the average figures of POH booking from your yards and how the figure is
to be kept in check? Make a critical study over a 15 day period to assess the wagons awaiting
heavy repairs on your division to indicate whether it is showing an increasing trend. Do you

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consider the existing repair facilities on your division adequate for the load arising. Are there
original foundations in your work load arising (Attach Sheet).

6.

Critically study detachments en route due to wagon defects. Analyze them cause wise and write
a report to suggest remedial action. Are there some seasonal variations.

7.

What is the procedure adapted to clear way side detached wagons?

What is the average

detention at way side stations? What is the incidence of repeated detachment of such wagons
(Attach Sheets)?

8.

Study the ineffective wagons laying on your division and categories them accordingly to the
number of days they have been lying ineffective. Propose a plan action to deal with the problem
in two page report with facts and figures (attach sheets).

9.

What are the rules regarding booking of heavy repair NPOH wagons to shops? Examine the
repair facilities provided on your division to deal with such heavy repairs arising if this work load is
considered important.

10.

Spend one full day at a major siding say FCI or an OIL siding or a tripper siding. Examine the
records of placement and removal of loads, loading/unloading facilities, system of handing over
and taking over for working out the damages and efficiencies and any other point of managerial
interest. (Attach sheets).

11.

Study LPG loading/unloading facilities, if any provided on your division including the safety
aspects.

12.

Study the special precautions for loading/unloading or passing POL rakes through your division
including a personal examination of all the fittings of a petrol tanks wagon on the diaphragm and
at the bottom discharge point. Examine the calibration, dipstick measurements and commercial
aspects of POL traffic. Mention important observations (Attach sheets).

13.

Inspect the complete provision of ARTs of different classes and ARMEs on your division and
the complete system on pressing them into service in case of accidents. Study the monetary
incentives to the break down staff. Are these adequate, inadequate or contra-productive?

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14.

Accompany a break down special from beginning to end to attend (a) a yard derailment, (b) a
mid-section derailment and write your individual report for inadequacies observed, avoidable
delays encountered, unsafe practices noticed and your suggestions for remedial action (attach
sheets).

15.

Examine critically and attach your complete report in case of failure of (i) plain bearing axle box ,
(ii) roller bearing axle box, (iii)Spring, (iv) Screw couplings etc. (attach sheets).

16.

Attend a case of train parting at site if possible or follow up a train parting enquiry case fully from
first information to imposition of penalty to a staff held responsible.

17.

Over a seven day period analyze the cases of sick marking cause-wise, location wise, type wise
and component-wise. Analyze also whether generation of sick marking for time based repair/
replacement etc. is commensurate with your total wagon dealing (attach sheets).

18.

Study in detail the material control system including sanctioned imprested, their recoupment
generation of timely alarms etc, write your assessment of equipment of 50 most vital items and
the system for ensuring continuous supply. (Attach sheets).

19.

Study critically the following services available in your sick line and write a descriptive brief with
your suggestions for improvements (a) hand tools, (b) pneumatic tools (c) compressed air supply.
(d) Welding plants, (e) INDUSTRIAL GASES, (F) MATERIAL HANING EQUIPMENT. (Attach
Sheets).

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CHECK LIST FOR DIVISIONAL AND WORKSHOP PRACTICAL TRAINING

15.

FOR IRSME PROBATIONARY OFFICERS

Checklist of items to be seen /studied in the field-training by IRSME Probationers is given below.
The list may be shown to the in-charge of the places where they are sent for training, and their cooperation sought. The probationers are expected to maintain daily diary during the course of
their training and submit their report on the aspects given below at the time of the assessment.

1.

Workshop: (Other than Diesel POH, Coach POH and Wagon POH)
1.1
1.1.1.

Accounts Office
Costing of work order. What inputs are required? How overheads are

calculated and

distributed? What different overheads are taken into account? Give a practical example.
1.1.2.

How are workshop manufacturing suspense (WMS) and Stores suspense calculated?
What entries are made in which suspense head when (a) material against a new work
order is released and (b) a work order is closed (finished material is deposited in the
stores against a work order)?

1.1.3.

How are issues notes accounted for? What is pairing of issue notes?

1.1.4.

How is budgetary control exercised in a workshop?

1.1.5.

What is a stock sheet?

1.1.6.

What is discounted cash-flow (DCF) technique and where is it used? Give an example
from the workshop you have been associated with.

1.2

Stores Depot

1.2.1.

How and when are stocked-items recouped? What forms/formats are filled up? What does
the procurement of stocked items?

1.2.2.

When a supply is received against a Purchase Order (P.O.), what process does it go through
before being taken in the stock ledger? What documents are generated iin the process, and
also when it is entered in the ledger?

1.2.3.

How is a new item stocked (made into a stocked-item), and what are the conditions to be met
before it is done?

1.2.4.

What is the procedure for issuing material against various work order?

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1.2.5.

What happens when material is deposited by the workshop against a stores work order?
What documents are generated in the Stores Departments?

1.2.6.

What are the current powers of the Stores Depot in-charge (of the Depot you were attached
to) for the procurement of stock items, non-stock items, and stationary items and DGS&D
rate-contract items?

1.3

Production Control Organization

1.3.1.

Planning

1.3.1.1.

What planning function is carried out in PCO and how?

1.3.1.2.

What steps are taken before a new work order is released?

What documents are

released along with the work orders?


1.3.1.3.

What are standing work orders? What is the difference between a green work order and
a stores work order?

1.3.1.4.

If a new item is to be developed, what steps are required to be taken?

1.3.1.5.

What is rate-fixing? What is the importance of work study, method study? Time study for
rate-fixers? How is rating of a worker arrived at?

1.3.1.6.

What is standard time for a job, and how is it arrived at?

1.3.2

Incentive

1.3.2.1.

What pattern of incentive is followed in the shop you were attached to?

1.3.2.2.

What is group incentive and how is it different from individual incentive?

1.3.2.3.

When is worker allowed to clock idel-time?

1.3.3.

Progress:

1.3.3.1.

What is the function of progress section? How is it carried out? What interfaces with the
shops are used?

1.3.3.2.

What documents are generated by this section?


document by progress section?

1.3.4.

Inspection:

1.3.4.1

What is the role of inspectors in the workshop?

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What entries are made in which

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1.3.4.2.

What happens if some quantity of manufactured item fails in the section? How is the raw
material used in the defective places recouped/accounted for? How the deficiency is
made good?

1.4.

Lab Testing:

1.4.1.

What destructive and non-destructive tests are carried out for testing of raw materials
received for inspection? Check for testing of ferrous, non ferrous, rubber/plastics and
paints/lubricants/chemicals?

1.4.2.

What tests are carried out on failed components for analyzing the failure? Give an
example of a failed component analyzed by the lab. And comment on the methodology
used.

1.4.3

What are photo-micrographs used for? See the structures of cast-irons, steels and some
non-ferrous material under the microscope. Identify the various micro-structures.

1.4.4.

Associate with ultrasonic testing of axle and try to follow the method of calibrating the
machine, checking of echoes, and differentiating between an echo and nose.

1.5.

Millwright:

1.5.1.

What system of preventive maintenance of M&P is being followed in the workshop to


which you were attached? What information system exists to know the breakdown of a
machine? Analyse the breakdown of machines in the previous week (from the records
kept) and comment on the efficacy of the system.

1.5.2.

What records are being maintained by the MTS for predicting the failures, or for
scheduling the preventive maintenance? Do they maintain history sheet of the machine?
How is the information- retrieval system? What use is made of the past information about
the trend of failures/symptoms showed by the machines?

1.5.3.

What is the structure of Millwright organization?

Who maintains the electrical sub-

systems of the machine? Who maintains the electronic controls of the sophisticated
machines in the workshop?
1.5.4.

Are their CNC MACHINES IN WORKSHOP? If yes, then how are they maintained?

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16

Divisional (Control Room) Working

1.1.

Attend a derailment/accident/yard derailment if it takes place during your attachments with the
division. Arrange with the power control to intimate you about such happenings even if they occur
at night. Write a report on the working on the site and the work of various agencies. You may
mention about any co-ordination between various agencies noticed during relief/rescue process.
Note the working of the relief/rescue equipment.

1.2.

Spend two hours in each of the shifts with the section controller (SCOR).

Preferably take

different sections for different shifts. Make your charts for the period and try to provide crossing/
precedence in your own chart and compare with the actual. Keep record of the date/time of the
section, name of the SCOR and the section/division railway. Analyse the actual chart to see if
there were any unnecessary delays/bad planning.
1.3.

Spend two hours in each of the shifts will the power controller and the TXR controller. Keep a
record of the activities.

1.4.

Study the morning position of Sr.DME (P) and Sr.DME (C&W) (or the DMEs if they are incharges). How are they collected, compared, delivered when the officer is out on line and used?
Also see the position of operating department and see the points of dispute and the source of
information. Can the disputes be avoided? Give your comments along with the reasoning.

1.5.

Calculated diesel/electric loco utilization for any day. How are shunting hours taken into account?

1.6.

Calculate the outage of a diesel/electric loco shed of the division, as well as the averages outage
on the division (including home/foreign railway locomotives). Also calculate average speed of
goods train from the chart for any day.

1.7.

Go through DRMS PCDO to GM for the previous three months and note down the salient features.
Do you feel any redundant information is being sent to the GM?

1.8.

Spend a day at the fueling installation (other than in a diesel shed) and record your observations.

1.9.

Examine 5 cases of punctuality loss and try to analyze the reasons. Compare your reasons with
the official version of the division.

1.10. Examine crew link and rake line of the division (attach copies). Compare the crew-link with the
guard line. Are they different? Why? Discuss with the Sr.DME/Sr.DOM.

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17.

GUIDE LINES FOR ZONAL TRAINING OF IRSME PROBATIONERS


Probationer should note that the zonal training is one of the most important parts of the
probationary training. Probationers are supposed to undergo this training at their allotted zone.
If zone allotment is not finalized by Railway Board probationers will be sent to tentatively allotted
zones (only for training purpose).
During the zonal training probationers has undergo thorough training covering following area:

Head Quarter working

Divisional working including coordination activities, working of power and C&W control
offices, Crew Lobby, Running Room, foot plate inspection, RCD, ART/ARME/CRANE etc.

Coaching Depot management and maintenance practices.

Freight Depot and examination yard management and maintenance practices.

Diesel Shed management and maintenance practices.

Workshops pertaining to the zone.

any other area nominated by the zone.

The individual guideline given for above areas is also applicable for the zonal training along with
specific guide line, if given, either by IRIMEE or by zonal authority. Additional guidelines for foot
plate inspection, Crew booking lobby etc are given below:
A)

Foot Plate Inspection: (Request concern authority to depute accompanying Loco Inspector along
with you)
i)

Various checks being done by Loco Pilots and ALP while taking charge of loco and
during train operation.

ii)

Signal sighting and exchanges of signal.

iii)

Safety (Loco and Engine)

iv)

Critical observation of driving technique ( Engine_man_ship of LP).

v)

Caution orders and their observance by LP.

vi)

Engine starting and loco operation.

vii)

Various records being maintained by the crew.

viii)

Crew monitoring by the Loco Inspectors.

ix)

Study of working time table

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x)

Entry of loco defects in repair book.

xi)

Running Room Maintenance and up_keep (With permission from Sr. DME, after the Foot
Plate Inspection stay at least once day in Running Room)

B)

C)

D)

Crew Booking Lobby


i)

Crew booking procedure, HOER, Principle of FIFO and statutory rest.

ii)

Technique of crew management, various mandatory training and Road learning.

iii)

Various Registers and instructions.

iv)

Procedure and Formalities during signing on and signing off , Breath analyzer.

Power Control and C & W control


i)

Role of Power Control and C & W control offices.

ii)

Control chart: Ideal time, actual chart, statutory train

iii)

Power plan and engine utilization, Goods loco movement

iv)

Over due schedule monitoring and movement

ART/ARME/CRANE

i)

Location and Composition.

ii)

Various equipment and their function.

iii)

Inspection Schedule and items of inspection.

iii)

Timing of actual movement.

iii)

Double exit line availability

v)

Nominated staff.

vi)

Details of previous mock drill and its importance. Etc.

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18.

LIST OF PROJECTS

A. PROJECTS FOR GRADUAGE STUDENTS


1.

Feasibility of use of Thermal Vision Cameras for fault diagnosis of locomotives/coaches/Wagons/


Machines.
Advanced distant vision thermal cameras are now available for industrial use that can give
temperature readings to the accuracy of +- 10 degree Celsius. Such cameras are currently in
use with BSES/Tata Power for detection of faulty cables in Delhi by measuring the temperature
differential. Feasibility of their use can be examined for detection of hot axle during examination
of a train when it rolls with a station. OR diesel locos with high exhaust temperature, OR faulty
cables on coaches/induction motors in workshop machines.

2.

Development of derailment warning system on Wagons/Coaches

Whenever derailment occurs on account of defects in a coach or wagon distress signals are given
out by the stock much before the occurrence of catastrophic failure. It is possible to capture some
of the signals like offloading of a wheel due to any reason or violent vibrations (some times a
wagon is dragged for several hundred meters before affecting other wagons but the driver comes
to know about the derailment only when pipe gets disconnects). Load cells/strain gauges, which
give such indications, are being actually used in safety circuits of sophisticated CNC machines
brake SPMs in our workshop to disable the machine in case of excess load on any drive/
violent vibrations etc. Feasibility of using such systems on coaches and wagons, so as to apply
emergency braking in case of distress can be examined.
3.

Provision of Analogue/Digital type Fuel oil/Lubricating oil and expresser oil level indicator in the
Drivers cab of Diesel Locomotives.
For taking fuel oil/lube oil and expresser oil level reading, engine crew has to walk on the foot
board around the stationary or running locomotive. This poses difficulty particularly during nights
and rainy season. Also the least count of these readings is too course (50 liters for fuel oil, 25
liters for lub. oil). Development of design with On Board digital readouts for modification in
existing locos will make this task easy and eliminate approximations in readings.

4.

Anti Climbing design on the footboard of Diesel Locomotives


The footboard is provided on a diesel locomotive to permit space for Asst. Driver/Maintenance
staff to carry out checks on engine portion of the locomotive. It is also required to give clear
view to crew driving from the long hood. However, it has become a favourite riding place for
unauthorized passengers in Eastern/Northern parts of the country, which is a cause of adverse
publicity for the Railways too. These unauthorized passengers also become the first casualty
when an accident occurs.

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5.

Feasibility of using night vision devices for Train Examination Personnel


Examination of coaching stock/wagon stock in poorly lit yards has been a problem, which has
defied solution. Possibility of use of night vision devices (produced by ordnance factory board for
defense forces) can be examined.

6.

Noise level in Coaches


Low noise level in passenger coaches is not perceived as an essential requirement.

With

international association of European Railways specifies noise level in various types of coaches,
no such standards have been laid down in Indian Railways for AC coaches and non air-condition
coaches. The challenge posed in reduction of noise in AC coaches is difference from that in nonAC coaches type. In non AC coaches, the noise generation and transmission is mostly air borne
while in case of sealed AC coaches, it is essentially for structural vibrations. Steps are required
to be taken to contain both structure borne and air borne noise. The noise that emanates from
various equipments (fans, compressor, ratting of doors, fixtures etc) also significantly add to the
passenger discomfort and this area is also needed to be looked into. The mechanical engineering
department of IIT/Roorkee has a sound lab and a vibration lab and they do a lot of analyze in
these fields. A project for measurement and reduction of noise level in coaches of various types
may be undertaken by their students.

7.

Headlights of locomotives for high-speed train operation


The intensity of light should be adequate to make the Drivers operate trains at a speed of 130
kmph or higher with confidence and safety. Focusing of the headlight is an area that needs much
improvement. The headlight (due to its colour or frequency) should be capable to dispense with
cattle or animals in such a manner that blowing the whistle iis altogether avoided in the middle
of the night when train passengers as well as the villager or citizens around the rail track are
asleep. Such light may also be utilized in daytime to disperse cattle or animals in daytime, as the
frequency of focused light should be such as to irritate the cattle.

8.

Horn of the locomotives


The horn/whistle of the locomotive should be designed at a frequency that deters and drives
away cattle.

The frequency should make the cattle feel uncomfortable but not the traveling

passengers or the inhabitants of the area around track. If the sound of horn/whistle (due to its
pitch or frequency) can make the cattle or animals move away from tracks, cattle run over cases
and resultant accidents and delays to trains will be avoided.

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9.

Emission norms for the Diesel Locomotives


Ensuring the emission norms for the Diesel Locomotives in tune with Euro IV standards is needed
for greener environment. The black smoke and unburnt fuel that emits from the chimney of a
diesel locomotives at part loads also needs to be taken care of.

10.

Ensuring of NIL Stock-outs of Spares and Components


Inventory control for the sake of ensuring all time availability of quality spares can be taken up as a
project. Despite existence of a separate organization Railways are plagued by the non-availability
of quality spares, such non availability affects the quality, reliability, traffic-availability and out turn.
Present system of indenting, tendering, procurement and inspection needs a thorough overhaul for
availability of quality spares, and at the same time carrying least inventory.

11.

Door-closers of Air-conditioned Coaches


Every air-conditioned coach is provided with door-closers that often goes out-of-door enroute.
Need for evolving a well-designed and sturdy door-closer that can be replaced after every 18
months or at the time of periodic overhauling (POH) immaterial of its condition. Door-closers
need to be maintenance free and totally devoid of failure of any kind between the successive
overheads of the coach.

12.

Best age for Driver of Supe4r-fast Trains


The locomotives of the trains are manned and operated by a Driver and an Assistant Driver. After
induction/recruitment as an Assistant Driver at a maximum age of 28 years, an assistant driver
can become a driver of mail and express train only when he/she has reached an age of over
45 years. In case of Rajdhani Express, Shatabdis or even the super-fast trains, the age of the
driver becomes over 50/55 years. The agility, reflex, prompt decision making capability, stamina,
endurance and efficiency which are required to a great extent while operating the super-fast
trains, Shatabdis and Rajdhani Express are usually in the wane at an age beyond 45 years or so.
A study may be under taken regarding (a) be best age (b) required qualification, (c) duration of
training, (d) method of recruitment etc .for drivers of the super-fast trains, Shatabdis and Rajdhani
Express.

13.

Material Handling and Lay-Outs


Material handling of wagon periodic overhaul (POH) shop or a routine overhaul (ROH) depot
needs streamlining. Modern material handling gadgets and equipments are to be incorporated
for improved productivity and better quality of out-turn. Even the layout of the shop or depot may

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have to be made different with a view to optimize the handling of materials and components.
Improved material handling should reduce the POH or ROH cycle time and require less of the
covered space. A carriage POPH shop or a Diesel Locomotive Shop or a Shed may also be
studied.
14.

Cordless Train Connectors


Development of infra red based, wireless inter coach connectors to transmit/receive 50 channels
of digital information from one end of the train set to the other end to provide inter loco multiple unit
coupling between the loco at the front of the train and the rear loco, driver and guard audio video
communication and announcement cum music channel in all coaches.

15.

Level Crossing Accidents


The diesel locomotive horn should be designed such that it targets the intending road users at
level crossing situated 300-500 ahead. Towards this end, the whistle should have a long and
telescopic range.

16.

Material Technology
The latest trends in new material technology may be exploited in order to:

17.

(a)

Reduce tare weight of our wagons, thereby increasing pay load.

(b)

Tare weight of the locomotives, without compromising on strength

Adhesives that can replace welding and other outdated techniques.

(d)

Adhesive as a repair solution for water tanks and such other less stressed equipments

Thermal Tell Tales


Higher level of stress is experienced only when the trains are running at full speed or running
with heavy loads on gradients.

The assemblies/components of the locomotives/components

of the locomotive coaches/wagons are, however, checked only when the train return to parent
line and is at standstill in the terminal. The maintainer, thus, does not get any clue as to the
thermal overloads suffered by bearings and other vital components during the run. Chemical
technology has come up with solutions in the form stickers that change colour permanently at a
predetermined temperature.
18.

Vibration Tell Tales


Similar requirement is there for detecting components that vibrate abnormally enroute but escapes
detection at the terminals.

19.

Stench Bombs
The roller bearings on the wheels sometimes fail due to breakage of rollers, cages, want of grease
etc. The baring becomes red hot and disintegrates. The axle breaks eventually, over a run of

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20 to 30 kms. Serious derailments with attendant loss of lives occur on this score regularly, in
early days, a chemical capsule was inserted in the grease. This capsule would disintegrate at a
redetermined temperature and the entire surroundings were filled with an offensive smell. The
guard. The passengers and station staff become alert and stopped the train, within the 20 to 30
kms of final breakdown. If this capsule is reinvented, we can save lot of lives and property.
20.

Fastener Technology
There are enormous opportunities to redesign a number of fastener joints, modifying their profile,
elongation, material, torque value etc., so that they remain fastened for long periods, without
becoming slack unexpectedly and causing failures.

Evolving Tele Tale designs to detect

fasteners that are in the process of becoming slack will also be a great help.
21.

Alternate Methods of Air Conditioning


The vapor compression cycle of air conditioning of our coaches & maintenance intensive and
needs constant supervision of trained artisans specially engaged to travel in the coach. Alternate
thermodynamic cycles for cooling the coaches with better economies may be evolved.

B. LIST OF PROJECTS FOR IRSME PROBATIONERS ON DIESEL FIELD TRAINING


DLW
1.

Make out plan to enhance chrome plating shop out turn by about 10%, having same no of staff
with the help of (a) reduced rejection, (b) increased painting bath & other equipment or (c) any
other method.

2.

Critically analyze the improvement (if any) by introducing welding qualification scheme, giving the
details procedure of weld qualification & wed lab.

3.

Study the product mix of DLW, Varanasi, giving the out turn in previous years. Mention the future
plan with respect to out turn (Product mix.)

4.

Study in detail all types of pipe joints employed in ALCO & GM locomotives draw sketches &
compare their merits, demerits and specific application.

5.

Study in detail the Huck Bolt of GM locomotive, the procedure for application and removal
advantages & disadvantages of this type of bolt, location where they are used & its working
principle with neat sketch.

6.

Study how the under frame of GO loco is different from Alco Loco & how is it manufactured?

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7.

a) Study the status of indignation of GM loco assy & subassy like P.P., compressor, traction
alternator, traction motor, invertors, SIBAS computer, EM2000 computer, high voltage cabinet
radar, small motors, bogie frame & other components.
b) Study the plan for reduction of cost of manufacture of G.M.Loco.

8.

Study & make out a simplified report of loco testing & pre departure inspection.

9.

Study the system of monitoring trial of assy & components in diesel loco. Find out the list of
items on trial and feed back received for some of them.

10.

Study the procedure of bulk indent by DLW. What items are indented through DLW & find out
cost of important items.

DMW/PTA
1.

Make out PERT chart for rebuilding/upgradation of locomotive at DMW. Find out the critical path
& suggest ways to reduce cycle time.

2.

Study

a) the procedure involved in manufacture of stiffer unit camshaft.


b) The differences in manufacturing with respect to conv.camshaft
c) Critical quality parameters &
d) Status of production

3.

Study the streamlined lube oil piping. Compare it with conventional piping with respect to a) lay
out (b) piping joints c) material d) cost & other factors if any.

4.

Study the upgradation of 2600 HP Loco to 3100/3300 HP at DMW/PTA. List out the changes
made by DMW for upgradation.

5.

Study the pressurization of loco control compartment


a) Why is it required?
b) How is it achieved?
c) Status

6.

List out all major assy. Subassy, & components. Find out its approximate weight & cost of
procurement. List out must change items during rebuilding of loco.

7.

Find out export job done so far by DMW, export potential & marketing effort of Loco.

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8.

Study the procedure of rehabilitation of bogie frame (by welding) including manipulator,
trammeling & welding quality check.

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DIESEL POH
1.

Find out the list of must change components, the philosophy behind each item, its compliance &
reason for deviations.

2.

Study the cycle time of POH of Diesel Loco. Suggest ways to reduce cycle time.

3.

a) Study the procedure for stocking a new item.


b) Study list of modifications, reason for modification, status & reason for non Implementation.

4. Study the procedure of feed back from Diesel Sheds regarding quality/failure of locomotive within one
year of POH. Suggest ways to improve the system of collecting feed back & system of corrective
action.
5. Study the cleaning component used for various components & for shop floor cleaning. Suggest the
improvement required keeping RDSO recommendations in mind.
6. Study expresser testing in detail in shop floor. Compare the practices with RDSO recommendations
(test plan) & mention reasons for deviation.
7.

Study the working, overhauling and testing procedure of air flow measuring valve.

8.

Study the working principle and overhauling procedure of reverser of the locomotive.

9. Observe final load box test after POH, reading taken & H.P. etc. and compare with recommended
practices suggest the improvement in the practices.
10. a) List out all the lain bearings & rolling bearings employed in the locomotive. Their exact type, size &
codes.
b) Compare the overhauling & inspection procedure of rolling bearing as practices against
recommended by RDSO or manufacturer.
DIESEL LOCO SHED
1.

Observe any light schedule, list out inspections, checks etc. done & compare with schedule card
independently. Find out deviations if any. Mention the reasons for deviations & suggest ways for
improvement.

2.

Make out a survey of major components removed during yearly, for example radiator core, L.oil
cooler, after cooler, TSC, TM, bogie frame, piston, Cyl. Hd etc. Find out date of manufacture,
date of last overhaul & present condition of the component/assy. Suggest ways to find out life of
the component.

3.

Collect data of Monthly failure of at least three component/assy. Over past five years, plot X, R
chart & derive inference.

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4.

Study met hod of (a) floating a seized wheel of the loco in the mid section, (b) removing pinion
from seized traction motor (c) isolating brake binding of a wheel.

5.

Study fuel installation records, registers and procedure of decanting & procedure of issue in
detail. What are important things to be checked during inspection of fuel installation?

6.

What are wheel records kept & with what frequency? Mention all the gauges used with neat
sketch & give actual record of a loco wheel during yearly schedule.

7.

Study ways to reduce wheel consumption from operating, maintenance & wheel turning angles.
Illustrate wheel turning instructions with the help of sketches.

8.

Observe various permanent & temporary data displayed in Diesel Shed Control Room. Suggest
ways to improve the display, the accuracy (updating) and communication to all concerned.

9.

Find out A category items of the Diesel Shed, its consumption & suggestions to reduce
consumption (of few of them.)

10.

List out all the test stands & inspection gadgets available in a Diesel Shed (Electrical &
Mechanical), its use & suggest further test stand required to improve reliability of the Assy/
component.

LIST OF PROJECTS ON C&W


Project of IRSME Probationers visiting RCF.
1.

2.

Shell manufacturing of AC coach with regard to:-

Manufacturing process

Total cycle time

Process and machine centers

Type of material used , Jigs & tools used

Material utilization

Incentive systems

Plant layout

Study of Bogie manufacturing covering:-

Manufacturing process

Total cycle time

Process and machine centers

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3.

4.

Note:

Type of material used

Material utilization

Incentive systems

Jigs & tools used

Plant layout

Testing method

Introduction of ISO 9000

Furnishing of AC Coach covering following items:-

Painting systems

Sequence of fitment

Intermediate checks/test

Various work centers

Cycle time

FE analysis on Bogie Design covering following aspect:-

Software used and hardware requirement

Method of FEA analysis

IS and international Standards used in comparing the values

Interpretation of data obtained after analysis

Test results

Material handling system covering follow items:-

Palletisation

Use of auto stacker

Machanised traverser

Remote control cranes

Use of dummy trolleys

Rail-cum road vehicle

Different types of fork lift trucks

Cost of equipment and time saving involved

Two-three probationers would form one group and one group work on only one project.

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Project for IRSME Probationers visiting ICF:1.

2.

Manufacturing of GS Coach Shell with regard to:-

Manufacturing process

Total cycle time

Process and machine centres

Type material used, Jigs & Tools used

Material utilization

Incentive system

Plant layout

Testing of finished coached covering following items:-

Air brake system

Furnishing

Safety items

Alarm system

Final acceptance, important quality checks for acceptance of coach by user


railways.

3.

Working of Sheet Metal shop.manufacturing shop with rest to following items:-

CNC machines, programming

Cutting diagrams used, optimizing material utilizations

Consumables used in CNC machines

Batch size and scheduling of components

Important sub-assemblies for which components are manufactured in SMS

Raw material used, type size, material specifications.

Note: Two-three probationers would form one group and one group work on only one project.
Project for IRSME Probationers visiting RWF
1.

Manufacturing of Axles covering following items:-

Manufacturing process

Total cycle time

Process and machine centres

Type of material used

Material utilization

Testing and inspection of axles

Material specifications

Quality control, defects and causes

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-

2.

3.

Costing

Manufacturing of wheels covering following aspects:-

New material used.

Process

Testing and inspection

Defects and causes

Cycle time

Working of plant maintenance group covering following aspects:-

Machines centres

Planning for scheduling machine maintenance

Monitoring of breakdown time

Planning for procurement indenting of important spares.

Unit exchange spares

Vendor development for spares

Annual cost of maintenance

Note: Two-three probationers would form one group and one group work on only one project
Project for IRSME Probationers visiting POH workshop
1.

2.

POH activities of coaches covering following items:-

Maintenance practices for POH

New modifications

Testing and inspections

Cycle time

Costing

Unit exchange of assemblies

POH of Roller bearing covering following items:-

Maintenance practices laid down by RDSO

Latest amendments

Actual practices

Deviations if any

Mounting and dismounting method

Inspections and testing

Cycle time

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-

3.

Costing

Repair attention to wheel sets covering the following items:-

Wheels and axle defects

Repairs and inspect to axles, profile for tyre turning and inspection.

List of wheels and axle

Inspection and testing

Cost of repairs

Project for IRSME PROBATIONERS VISITING Wagon POH Workshop


1.

POH activities of wagon covering following items:2.

POH of CTRB covering following items:-

3.

Maintenance practices laid down by RDSO


Latest amendments
Actual practices
Deviations if any
Mounting and dismounting method
Inspection and attesting
Cycle time
Costing.

Corrosion repairs top wagon covering following items:-

4.

Maintenance practices for POH


New modifications
Testing and inspections
Cycle time
Costing
Unit exchange of assemblies

Repairs practices laid down, types of welding repairs


Periodicity of attentions
Costing
Manpower r3equired
Material used
Time required for attentions
Water tightness test

Rehabilitation of Wagon with Stainless Steel covering following items:-

Criteria for rehabilitation


Procedure
Difference between BOXN & BOXN R Wagon
Dos & Dont

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19.

QUESTION BANK
A)

1.

C&W
What is ROH meant for? What are the checks done no bogie? How are cracks checked? Which

are the vulnerable locations where cracks are generally found? How is break beam reclaimed during
POH? How is staffing done for ROH Depot? Why is ROH of BOX N/BCN wagons done at a
periodicity of 18 months? What are the major items which require attention after this period?
2.

Why is there a plank in the Casnub bogie?

3.

CC rakes are required to run for 4500 KMs before train examination. Do the brake blocks last for
this distance?

4.

What are the major causes of defects on coaches noticed at PM depots and how can they
reduced?

5.

What are the reasons for biased wear on wheels?

6.

In ICF Coach, how is correct bogie height & the correct gap between bogie and under frame
obtained?

7.

Describe the shell construction of ICF Coach?

8.

Reasons for waviness in ICF Coach and remedies.

9.

Various welding processes used in ICF. Advantages of CO2 and Argon welding.

10.

ICF shell fabrication

11.

Painting in ICF shell. Sole bar painting

12.

Use of choke in ACP and in Guards van

13.

Steps in bogie manufacture at ICF.

14.

How should insulation is provided in coaches?

15.

Payload of Box N RAKE.

16.

What are mechanical and Electrical reasons of detachment and sick marking? Percentage of
Electrical/Mechanical?

17.

What C.C. rake and its B.P.C?

18. How much brake power is required for CC Rake?

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19. What is there in I.C.F.? Any major problem being faced in I.C.F. these days?
20. Is derailment possible due to breakage of spring?
21. Is there any CC rake in the division you have visited?
22. What is Shatabdis max. Speed and in which section?
23. How the bogie of Swaran Shatabdi different from other bogies?
24. Why spring is larger for Swaran Shatabdi? How does it increase riding comfort?
25. Tell about IR-20 bogie.
26. What have you seen in coaching depot?
27. Can U.I.C. rake be used as CC rake?
28. What is difference between passenger and goods outage?
29. What are reasons for train parting?
30. What is difference between single and twin pipe system?
31. Have you gone to RDSO? Have you seen Coaching Directorate?
32. What is the material of side wall panel in coach furnishings (Sunmica)? Dont you think it is too
fragile?
33. Have you seen cartridge bearings? What type of rollers it have?
34. What is the shock member inside buffer casing (destruction tube)? How does it function?
35. What are reasons for sick marking?
36. Tell about any case of sick marking.
37. What are reasons of bias wear and flange wear?
38. How load is transferred in BOXN?
39. Why no cases of bias wear found BEML coaches?
40. How high speed wagons are different from normal wagons?
41. What are reasons for spring breakage?
42. Where is dash pot located?

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43. Types of air brake system, explain.
44. Was twin pipe system used in wagons? Why single pipe now?
45. Why waviness is coming in ICF coaches these days?
46. What are the problems faced in bogie welding? What are various radiographic defects?
47. What is difference between UIC and Casnub bogies? Why is bias wear found in casnub bogie?
48. Have your seen BEML coaches?
49. What do your know about LHB Coaches?
50. Tell about the difference between the maintenance practices of Shatabdi and normal trains?
51. What are different types of casnub bogies and their differences?
52. What are the reasons of derailment of goods train?
53. What is cross trammeling? What is done to rectify the defect found during cross trammeling?
54. Mention various defects found in coaches.
55. Tell about suspension system of various coaches?
56. How is adjustment of side bearer done?
57. Have you seen the POH coaches?
58. How the POH of dash pot is done?
59. What is loading line?
60. Which rakes are being maintained in the coaching depot you visited?
61. What is the difference in maintenance practices between Shatabdi & other coaches? What are
RDSO guidelines for Shatabdi coach maintenance?
62. In the washing line, is there a list prepared for consumables required for each coach? What are the
items in such lists?
63. What are the salient features of the freight depot you visited?
64. What is the periodicity of ROH? What are the items of maintenance carried out in ROH?
65. What is the most corrosion prone area in BCN wagon?

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66. What is secondary detachment of a coach? What are the causes of secondary detachment?
67. What is axle box canting? Why does it happen?
68. What is the periodicity of dash pot oil check? When is oil filled in the dashpot?
What damage would occur if dashpot oil is less?
69. What sizes of wheel flat are allowed on coaches and freight stock? Why is the allowance higher for
freight stock?
70. What are composite brake blocks and what are their advantages and disadvantages?
71. In ROH of casnub bogies, what attention is given to pedestals?
72. What are A, B and C classes of unloadable wagon repairs?
73. What are CC rakes? Can wagon of CC rakes be re-positioned within the same rake before return for
maintenance?
74. What are the types of detachments for coaching stock?
75. What is the significance of sick marking of coaches within 90 days of POH?
76. Give details of project given to you at ICF?
77. If at ICF, coach is to be lifted by one crane only, how will you calculate the location of the lifting
slings?
78. Describe bogie manufacture at ICF.
79. What is the quantum of rejections in radiographic attesting of welds at ICF?
80. How is the stress relieving carried out on bogie frame after fabrication/welding at ICF?
81. What is the maximum time given between primer application and painting on a coach at ICF? What is
the harm if this exceeded?
82. Describe the procedure for water tank fitment on a coach at RCF.
83. Why are there cross sheets welded on the side of the shell of an ICF coach?
84. What is the reason for waviness on the skin if the shell of RCF and ICF coaches?
85. How are CTRBs fitted on axles at RWF?

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B)

DIESEL LOCO

86.

What are the most important items checked during trip schedule of Diesel Locomotive? What are
the steps which have been taken for increasing schedule interval for Diesel Loco?

87.

What is the main design feature of WDP2 locomotive and its speed potential? How and why is
high adhesion obtained? How many coaches can be hauled by this loco?

88.

Describe the bogie of WDG2. What is COCO and tri-mount?

89.

Difference between WDM2 and SDG2

90.

Slip in WDG4.

91.

Steps in loco POH.

92.

Cleaning of crankshaft.

93.

Functions of flasher light.

94.

What are three tiers of pit line?

95.

What do you know about dynamic braking principle?

96.

Where have you seen pit lines?

97.

What is difference between passenger and goods outage?

98.

Where have you done div. training?

99.

What is engine block manufacturing sequence?

100.

What is flow meter?

101.

Have your seen WDS4?

Where does the POH of industrial WDS4s done? (Belonging to

industries).
102.

What are various types of side bearers?

103.

What are various loco schedules?

104.

Tell something about working of diesel shed?

105.

What are trip schedule items of loco?

106.

How GTKM is calculated?

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107.

What do you know about honey comb? (Cylinder liner).

108.

How is crank pin tightened? Why is it prestressed?

109.

How is axle surface finish checked?

110.

What do you know about UST testing of Axles?

111.

What are the problems faced ion bogie welding? What are various radiographic defects?

112.

How is goods loco outage calculated?

113.

What are various types of side bearers? Where are they used?

114.

What are the details of the transmission systems and power packs of various shunters used in IR?

115.

What is done in DMW?

116.

What is the traction motor winding sequence?

117.

What are the activities of trip schedules?

118.

How is adjustment of side bearer done?

119.

In which schedule the turbo supercharger overhauled?

120.

What are the features of a WDG4 Locomotive?

121.

What are the maintenance advantages of a WDG4 Locomotive?

122.

What are the differences between WDP2 and WDM2C locomotives?

123.

How is speed controlled in a locomotive fitted with AC traction motors?

124.

Will increase in horse power of a locomotive allow increase in hauling capacity?

125.

How has adhesion been increased on the WDG4 locomotive?

126.

What an arrow indicator?

127.

What is the different between dynamic, rheostat and regenerative braking?

128.

In Diesel loco engine manufacture at DLW, how is stress relieving done and how is radio graphic
testing done?

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OPPERATING
129.

What does power controller of the division do? How can the power controller help in controlling
fuel consumption? How is requirement of crew worked out for goods train? What is the essential
running room facilities required to be provided?

130.

What is roster hour of driver?

131.

Working hours of driver.

132.

How much brake power is required for CC Rake?

133.

What are the functions of power controller?

134.

What is Shatabdis max. Speed and in which section?

135.

How the crew requirement calculated?

136.

What are the reasons of train parting?

137.

What is ideal engine utilization figure?

138.

How is crew booked?

139.

How can you calculate and reduce O.T. of Crew?

140.

What is crew balancing?

141.

What is grand chord and its significance?

142.

Delay in mid section, action needed regarding ART & ARME.

143.

What is 10 hours rule?

144.

What is BPC?

145.

How is loco utilization calculated in the division you have visited?

146.

On foot plate, what indications have you observed for run through train being received
On loop line at a B class station?

147.

What does the driver do in case of leakage indicated on airflow indicator?

148.

What are the duty hours of a driver?

149.

When can a driver ask for relief?

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150.

What are the roster hours of a driver?

151.

How is payment of overtime to a driver to be avoided?

152.

How is payment of overtime to a driver to be avoided?

153.

What will the driver do if there is brake binding after ACP?

154.

What does a wheel de-rail?

SIGNALLING
155.

What is the status of advance starter, starter, home, distance when a train is required to run
through the station?

156.

Aspect of distant signal.

157.

What is inner distant signal?

158.

What are the signals at a B class station?

159.

In multiple aspect colour light signaling, what do yellow and double yellow indicate?

160.

With multiple aspect colour light signaling at B class station, for run through train coming at more
than 10 KMPH speed, is one distant; signal adequate?

161.

What is a calling on signal?

162.

What is VVF?

GENERAL
163.

How will you decide the periodicity of a maintenance schedule?

164.

What is demand 10?

165.

What are the demands for grants for Mechanical Department?

166.

What is operating ratio and what are the current figures for the different Rlys?

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20.

LIST OF CODES, MANUALS AND OTHER PUBLICATION


A. LIST OF ENACTMENT/CODES/MANUALS/PUBLICATIONS

Sl.No.

Title

1.

IR Code for the Mechanical Department (Workshop) - 1991

2.

IR Maintenance Manual for Diesel Locomotive 1978

3.

IR Maintenance Manual for Wagons March 2001

4.

IR Maintenance Manual for BG Coaches 2002

5.

Maintenance Manual for WDM2-Feb, 1992, DLW

6.

Maintenance Manual for YDM4 (MG) Feb, 1992, DLW

7.

Maintenance Manual for WDS6-Feb,Feb, 1992, DLW

8.

Maintenance Manual for WDP1-Feb, 1998, DLW

9.

Maintenance Manual for WDG2- Feb, 1998, DLW

10.

Maintenance Manual Electric Equipment for WDP1 (AC-DC) System)

11.

HTSC Bogie of GT46 PAC/MAC Loco Service Manual

12

IR General Rules 1976

13

Accident Manual (By each Railway)

14

IR Code for the Stores Department Vol-1

15

IR Code for the Stores Department Vol-1I

16

IR Financial Code Vol-I

17

IR Financial Code Vol-II

18

IR Financial Code Vol-II Appendices

19

IR Code for the Accounts Department Pt-I

20

IR Code for the Accounts Department Pt-II

104

Guidelines for IRSMEProbationers, IRIMEE/ JMP


21

IR Administration and Finance An Introduction

22

IR Establishment Manual Vol-I

23

IR Establishment Manual Vol-II

24

IR Establishment Manual Vol-I

25

IR Establishment Manual Vol-II

26

IR Code for the Engineering Dept.

27

Permanent Way Manual 1986

28

IR Bridge Manual 1998

29

IR Code for Traffic (Commercial) Department

30

Railway Servants (Pass) Rules, 1986

31

Railway Servants (Pension) Rules, 1993

32

Railway Protection Force Regulations, 1966

33

IR Medical Manual

33

Manual on Management Training

SOME OTHER IMPORTANT MANUALS/BOOKS RELATED ATO MECHANICAL DEPARTMENT

Sl.No.

Title

Published by

1.

Diagram Book of WDM2

RDSO (MP)

2.

Diagram Book of WDG2 (RDSO MP MISC-101 Sept 2000

RDSO (MP)

3.

Diagram Book of WDP1

RDSO (MP)

4.

Diagram Book of WDP2

RDSO (MP)

5.

Diagram Book of WDM2c

RDSO (MP)

105

Guidelines for IRSMEProbationers, IRIMEE/ JMP


6.

Diagram Book of WDP2

RDSO (MP)

7.

Diagram Book of WDG4

RDSO (MP)

Trimount CO-CO Bogie Manual RDSO MP/MI-71/78 (Modified July

RDSO (MP)

8.

1992)

9.

High Adhesion WDG2 Bogie: VL.MI 02/96

RDSO (MP)

10.

WDP2 Bogie MANUAL: vl.mi-04/98

RDSO (MP)

11.

Wdg4 Bogie Section 7 of GT46 MAC/PAC Loco Service Manual

GM USA

12.

Compendium of Instructions (Diesel Traction)

Rly. Board

13.

Compendium of Instructions (Freight)

Rly. Board

14.

Compendium of Instructions (Coaches)

Rly. Board

15.

Compendium of Instructions (Freight)

CAMTECH

16.

Compendium of Instructions (Coaching)

CAMTECH

17.

A technical guide on derailment

CAMTECH

18.

Load Box Parameters

CAMTECH

19.

Hand Book on Diesel Locomotive

CAMTECH

20.

Trouble Shooting Guide of Diesel Locomotive

CAMTECH

21.

IRCA Conference Rules Pt.III (Under issue)

IRCA

22.

IRCA Conference Rules Pt.IV (2003)

IRCA

23.

140 Tones Diesel Crane Maintenance & operation manual

106

Guidelines for IRSMEProbationers, IRIMEE/ JMP


21.

CHECK LIST FOR INSPECTION (RAILWAY BOARD)


Railway Board has issued a detailed Technical Checklist to be observed/follows during inspection

of Diesel Shed, Crew booking points, Fuel inspection, Foot plate inspection, Coaching Depot, ART,
Running Room, Sick Line etc. The checklist is available in all the units and in IRIMEE Library. The list is
quite exhaustive and useful for IRSME Probationers.

22.

CONTACT PERSONS FOR FIELD TRAINING

Sl.No.

Field Unit

Officer

1.

Rly. Board

ED (Trg & MPP), Room No.370, Jt. Director /Esst.

2.

RSC/Vadodara

Secy. To DG

4.

RCF

Dy.CME/HRD

5.

DMW

Dy.CME (S)

6.

ICF

CDE

7.

RWF

CWE/G

8.

DLW

Principal Technical Training School

9.

NDLS

Sr. DME (C&W)

10.

MGS

Sr. DME/MGS

11.

RDSO

Director (Motive Power , Carriage & Wagon)

12.

DLS VSKP

Sr. DME/Diesel

13.

Diesel Shed, Hubli

Dy.CME/ Diesel Shed

14.

DLS/TKD

Sr. DME (Dsl)

15.

GOC WS

WM/D/ESEL

16.

Coaching Depot
BBCT (WR)

17.

CON/COR

19.

Sr. CDO
GM (Tech)
ADGTA (Army Directorate)

Territorial Army HQ
GS Branch Army HQ, L Block, Church Road, New Delhi

107

Guidelines for IRSMEProbationers, IRIMEE/ JMP


23

SYLLABUS OF IRIMEE COURSES


1.

Sl.

COURSE NAME

: C&W Introduction

COURSE CODE

: CWIN

DURATION

: 1 WEEK

COURSE CONENT

: Following topics may be covered during this session:

Subject/topic

Role of C&W in the Railways

C&W stock identification

C&W Organization in Railways

Name+Role of Coaching Shell (excluding furnishing) components

Name + Role of Coaching Passenger Interface Items

Name + Role of Wagon (body only) components

Name + Role of Bogie components

2.

Sl.

COURSE NAME

: Diesel Technology Introduction

COURSE CODE

: DTIN

DURATION

: 1 WEEK

COURSE CONENT

: Following topics may be covered during this session:

Subject/topic

Role of Diesel traction in the Railways

Types of locos and their characteristics

General Arrangement -diesel loco

Major loco assemblies

Basic Loco operations

Diesel organisation on the railways and Maintenance philosophy

GM Loco Intro

Visit to Simulator

Visit to shed and workshop

108

Guidelines for IRSMEProbationers, IRIMEE/ JMP

109

Guidelines for IRSMEProbationers, IRIMEE/ JMP


3.

Sl.

4.

COURSE NAME

: Power Electronics

COURSE CODE

: PECS

DURATION

: 1 WEEK

COURSE CONENT

: Following topics may be covered during this session:

Subject/topic

Concepts-Electrical

Concepts-Semiconductors and ICs

Concepts-circuits

Concepts-DC and AC drive

Concepts-AC controls - VF, VVVF

Switchgear - types, common issues

Power Supply Systems

Mtc + testing Infrastructure

COURSE NAME

: Mechatronics

COURSE CODE

: MEKX

DURATION

: 1 WEEK

COURSE CONENT

: Following topics may be covered during this session:

Sl.

5.

Subject/topic

Concepts - hydraulics + electro-hydraulics

Concepts-using documentation

Power Electronics revisited

Introductionb to digital Electronics

CNC Drives + their Control Systems

Components of a CNC system

CNC maintenance, Record keeping

Weighbridges + WILD

WSP of LHB, CDTS

10

mechatronics frontiers
COURSE NAME

: Diesel Fundamental
110

Guidelines for IRSMEProbationers, IRIMEE/ JMP

Sl.

6.

COURSE CODE

: DFUN

DURATION

: 1 WEEK

COURSE CONENT

: Following topics may be covered during this session:

Subject/topic

Dsl engine fundamentals

Electrical Transmission on locos

governers

Loco Bogie

Air brake Systems including CCB

scheduled mtc

staff organisation for Loco Mtc

Failure investigation in Diesels

COURSE NAME

: Diesel System - ALCO

COURSE CODE

: DSAL

DURATION

: 1 WEEK

COURSE CONENT

: Following topics may be covered during this session:

Sl.

Subject/topic

Rotating Machines

Transition and motor control

Excitation system + dynamic braking

Compressor and compressed air system

MCBG, MEP

power pack

LV circuits

Load Box testing

Mech secondary systems

10

Modifictions

111

Guidelines for IRSMEProbationers, IRIMEE/ JMP


7.

Sl.

COURSE NAME

: Diesel System- GM LOCO

COURSE CODE

: DSGM

DURATION

: 1 WEEK

COURSE CONENT

: Following topics may be covered during this session:

Subject/topic

Mech secondary systems

Rotating Machines

power pack

Compressor and compressed air system

IGBT based EMD

Traction converter + SIBAS computer

EM2000

scheduled mtc

GM Loco testing

10

GM shed mgt

112

Guidelines for IRSMEProbationers, IRIMEE/ JMP


8.

Sl.

COURSE NAME

: Diesel Maintenance Management

COURSE CODE

: DMMT

DURATION

: 1 WEEK

COURSE CONENT

: Following topics may be covered during this session:

Subject/topic

reporting - Diesel shed/ workshops

matl mgt in a shed/ workshop

Locos - Dead and Alive

Shed and wshop layouts

Mgt of outtage

Interaction with DLW, DMW, Bd and RDSO

Load factor

works contracts in dsl mtc

T&P Mgt

10

Key infrastructure Mgt

113

Guidelines for IRSMEProbationers, IRIMEE/ JMP


9.

Sl.

COURSE NAME

: Diesel Technology- Others

COURSE CODE

: DTOT

DURATION

: 1 WEEK

COURSE CONENT

: Following topics may be covered during this session:

Subject/topic

Introduction to DMUs and their ops

DMU engine

DMU electricals

DMU controls and control systems

DMU Hydraulics

training of staff

Frontiers of Diesel Tech in Railways

DMU sch maintenance

DMU shed infrastructure

10

SPART/ SPARME/ SPARMV engine

11

SPART/ SPARME/ SPARMV transmission

12

SPART/ SPARME/ SPARMV sch mtc

13

Alternate fuel tech

14

RCRV

15

DG equipment

114

Guidelines for IRSMEProbationers, IRIMEE/ JMP


10.

Sl.

COURSE NAME

: Fuel, Loco Ops and crew mgt

COURSE CODE

: FLOC

DURATION

: 1 WEEK

COURSE CONENT

: Following topics may be covered during this session:

Subject/topic

Reporting - Divisions Ops

Costing of ops

Diesel loco/ DMU/ electric loco ops

Fuel Mgt

Power plan

Crew Management

Ops of Accident Relief vehicles

Establishment in loco ops

Running room mgt

10

Role and functions of CNL

11

train running concepts

12

Inspections & footplating

115

Guidelines for IRSMEProbationers, IRIMEE/ JMP


11.

Sl.

COURSE NAME

: Common Maintenance Practises in C&W

COURSE CODE

: CMCW

DURATION

: 1 WEEK

COURSE CONENT

: Following topics may be covered during this session:

Subject/topic

Working with SS in C&W

concepts of coating based corrosion protection

C&W mtc practises in open line and workshops

inter-vehicle connections

Corrosion Repair (C&W)

Bearing Tech

C&W Bogie mtc

Maintenance of brake system components

Station level passenger services

12.

Sl.

COURSE NAME

: Common Maintenance Practises in C&W

COURSE CODE

: CHGM

DURATION

: 1 WEEK

COURSE CONENT

: Following topics may be covered during this session:

Subject/topic

Coaching DesignConcepts

Safety in Coaches

Electrical aspects in coaching + dmu mtc

DMU mtc(C&W portion) specifics

Mtc of Coaching Shell

Mtc of Coaching Passenger Interface Items

LHB Maintenance

lhb specific mtc issues

116

Guidelines for IRSMEProbationers, IRIMEE/ JMP


13.

Sl.

COURSE NAME

: C&W Ops in Divisions

COURSE CODE

: CWOD

DURATION

: 1 WEEK

COURSE CONENT

: Following topics may be covered during this session:

Subject/topic

Reporting and Statistics C&W

introducing new trains/ stock for the first time

divisional C&W CNL functions

HQ CNL functions

New Trends in C&W

Private wagon mtc

commercial earning contracts in C&W

New wagon designs

Best Practises in C&W depot infrastructure

10

Linen Mgt

11

Works Contracts in C&W

12

Planning in C&W

117

Guidelines for IRSMEProbationers, IRIMEE/ JMP


14.

COURSE NAME

: Workshop Mgt

COURSE CODE

: WMGT

DURATION

: 1 WEEK

COURSE CONENT

: Following topics may be covered during this session:

Sl.

Subject/topic

civil infrastructure in mech units

Elect infrastructure

M&P and T&P Infratructure

Quality of Work done

Legal framework

Incentive schemes

Planning in Workshops

workshop layout

Reporting - workshops

10

C&W Masters

11

WTA and Bogie Mtc

12

Shop floor level material managerment

13

w/s specific establishment

118

Guidelines for IRSMEProbationers, IRIMEE/ JMP


15.

Sl.

COURSE NAME

: Disaster Mgt

COURSE CODE

: DISM

DURATION

: 1 WEEK

COURSE CONENT

: Following topics may be covered during this session:

Subject/topic

Disaster Mgt Org and Plg

causes + symptoms of accidents

After an accident

safety related training of staff

DM Eqpt and its mtc

Name + Role of important Gottwald crane systems

Gottwald crane operation at accident sites

Gottwald crane maintenance issues

New developments in ART

10

Accidents within Railway premises

11

Spl conditions at Accident Sites

12

Preparadness for accidents

13

Case studies

14

Investigating an Accident

119

Guidelines for IRSMEProbationers, IRIMEE/ JMP


16.

COURSE NAME

: Mech specific Material Planning

COURSE CODE

: MSMP

DURATION

: 1 WEEK

COURSE CONENT

: Following topics may be covered during this session:

Sl.

Subject/topic

Concepts - revisited

Matl plg - Role of mech

how to draw/ indent material

How to stock an item

Scrap Mgt

Responsibility of mech in Stores Tenders

Material Mgt monitoring

IT in stores

Role of mech in Vendor Mgt

10

Matl shortage

11

Best practises in Matl mgt

120

Guidelines for IRSMEProbationers, IRIMEE/ JMP


17.

Sl.

COURSE NAME

: Money value cases in mech

COURSE CODE

: MVCM

DURATION

: 1 WEEK

COURSE CONENT

: Following topics may be covered during this session:

Subject/topic

Basic concepts

Before intiation of case

Budgetting/ liability

Estimate creation

Sanction of a proposal

SCC in mech cases

dispensation of tenders

role of convener

Post acceptance activities

10

M&P/ T&P specific issues

11

Contract completion/ termination

121

Guidelines for IRSMEProbationers, IRIMEE/ JMP


18.

Sl.

COURSE NAME

: Mech specific Mgt Skills

COURSE CODE

: MSMS

DURATION

: 1 WEEK

COURSE CONENT

: Following topics may be covered during this session:

Subject/topic

ethics

Manual of office procedure

M&P program

Works program

Items in WP proposal

Accounting - revisited

Budgetting

expenditure and liability monitoring

Costing in workshops

10

Using SOP (NE)

11

Misc matters

12

Creation of posts

13

IT in estab & A/cs

14

Misc staff benefit/ welfare activities

15

Handling of officers below

122

Guidelines for IRSMEProbationers, IRIMEE/ JMP


19.

Sl.

COURSE NAME

: Computers and IT in daily use

COURSE CODE

: CIDU

DURATION

: 1 WEEK

COURSE CONENT

: Following topics may be covered during this session:

Subject/topic

Word Basics

Word Customisation

Excel Basics

Excel Graphing

Excel Data Analysis

Excel Formulas

Using Powerpoint

Using Databases

IT security for you

10

Networking basics

11

Specifying systems

12

Working with Images

13

CAD and FEA intro

123

Guidelines for IRSMEProbationers, IRIMEE/ JMP


20.

COURSE NAME

: Mechanical Specific CMT Issues

COURSE CODE

: MCMT

DURATION

: 1 WEEK

COURSE CONENT

: Following topics may be covered during this session:

Sl.

Subject/topic

Procedure of inspection

Metal testing

Other material testing

lab+test eqpt/ infrastructure

Welding Tech basics

Welding Stainless Steel

Weld quality issues

Corrosion basics

Corrosion prevention mechanisms

10

fracturography

11

failure modes

12

Case Studies of failure investigations

13

Pollution/ waste/ environtment issues

124