FARAKKA

FARAKKA

FARAKKA

INDEX
Sl.
No.
1

DESCRIPTION

PAGE No.

SCOPE OF TECHNICAL & SAFETY AUDIT

LAYOUT OF FARAKKA MGR & ITS BRIEF
DESCRIPTION
TECHNICAL AUDIT TEAM/INTERNAL TEAM TO
ASSIST THE MEMBERS

5-6

TRACK INCLUDING RECOMENDATIONS

7 - 13

LOCOMOTIVES

14 - 21

WAGONS

22 - 26

S&T

27 - 29

MGR OPERATION

30 - 36

OBSERVATIONS & RECOMMENDATIONS

37 - 40

FARAKKA

SCOPE OF TECHNICAL & SAFETY AUDIT

Following areas were covered for health assessment of MGR

System
Track Maintenance including bridges and level crossings.
Rolling Stock Maintenance System.
Operation System.
Signaling & Telecommunication System.
Allied Machinery and equipments.
Safety aspects in Operation and Maintenance of MGR system
including implementation of accident enquiry / technical audit
recommendations.
Other allied problems related with operation and maintenance
of MGR system.
System of condition monitoring and record keeping etc.

FARAKKA

LAYOUT OF MGR AT FARAKKA

Total Route Length

Total Track Length

: 84.50 Km
: 115.50 Km

LOADING POINT
C/ROOM: KM- 81.50
SILO-I & II

LALMATIA CABIN: 84.50 KM

20 KM

33 KM
BARHAIT
STATION

KUMARPUR
STATION

TH-I
TH-II

52 KM
PATHRA
STATION

MGR CONTROL ROOM

TO EXG. YARD

MGR FEATURES
FARAKKA MGR is longest single line MGR of 85 KMS length with
loop on both ends. This is operated by 3 intermediate full fledge stations
which is a unique feature in any of MGR in NTPC. Out of 85 KM track
length, about 10.5 KM consist of black cotton soil & low bearing capacity
soil, 2.25 KM high bank and 11 KM is very prone to be flood affected.
There is also a ruling gradient of 1:100 rising in empty direction and 1:200
rising in loaded direction. There are 286 no. bridges/culverts (15 no. major
4

FARAKKA
bridges), 49 no. curvatures and 66 no. of unmanned level crossing over
the track length.

TEAM OF TECHNICAL AUDIT:

Name of Auditor

Designation

Mr.M.V.Krishnan

DGM(MGR)Vindhyacha
l

Mr. C.S.Tiwari

DGM(MGR)Korba

Operation
& S&T

Mr.P.venkatramaiah

Sr.Supdt
(MGR)Ramagundam

Track

Mr. M.M.Manzer

Manager.(ER -I HQ )

Audit Area
Rolling
Stock

Coordination

FARAKKA

INTERNAL MEMBERS WHO ASSISTED THE AUDIT AREA:

Sl

Name of internal

No

Members
Shri B.K.Jha

01

Shri S. Roy
Shri Basudeb
Ghosh
Shri A.Chatterjee
Shri S.N.Ganguly

02

Shri Prabir Pal

Shri B.K.Sinha
Shri S.N. Sarkar

Audit Area
Designation

(MGR
System)

AGM (MGR)
Supdt (MGR)

Operation

Dy Supdt (MGR)
AGM(MGR)
DGM(MGR)
Sr.Supdt (MGR)
Dy Supdt (MGR)

Rolling
Stock, S&T
& Allied
System

Asst. Manager
(MGR)

03
Shri R K Sinha

AGM(MGR)

Shri N. Lodh

DGM(MGR)

Track
Maintenanc

FARAKKA
DGM(MGR)

Shri S.Das
Shri Subrato Das
Shri Shabir Ali

Manager (MGR)

Asst.Manager
(MGR)

1.TRACK
General

1.

Track length

: Load line 84.5 KM,

Total length including loading & unloading Bulb: 115.5
KM

2.

Ruling gradient : Empty direction 1 in 100

Load direction

3.

Track structure

- 1 in 200

: Rails 52 kg, T-12 quality

PSC sleepers with density of M+7.all along the track
except at 63/450 to 63/900 km which is with Wooden
& PSC sleepers in mixed condition and CST-9 in
patches for a total length of 1.1 km.

4.

Side slopes of formation on embankment: The track section

between Workshop to Pathra station was inspected by light engine on
10.09.2014.
a. The side slopes and formation on embankment is found to be OK in
general.
b. At some locations the repair of the cess is
earthwork.

5.

Condition of Sleepers:

necessary through

FARAKKA
CST-9/Wooden sleepers are being replaced with PSC by RITES
and nearly 1,03,200 sleepers(including spl.sleepers) are
replaced. Balance 1800 sleepers are expected to be replaced by
Nov14. This is to be done in approx. 1.1 Km track in total at
Kumarpur yard, Berhait & at Km 40/500 to 40/900.
At various locations excessive PSC sleepers are found which are
to be shifted to required locations..
At several locations of the entire length of the track as
mentioned in last audit, Rail burns, scabs were found on the
track. It is stated that 18 Km Rails shall be replaced by RITES
under the track renewal contract, out of which 16 km is already
replaced and balance qty is likely to be completed by End
Oct.14.

Ballast deficiency is still persisting :

As advised in last tech audit, site has procured 35000 cum ballast
from EC Railway out of which 32500 cum is received and spread in
track through Rly wagon already.
The track ballast got scanty from recent replacement of the
CST-9 with PSC by RITES .Further ballast procurement is
required to recoup the deficiency.
Track geometry to be improved by starting the Deep screening
of the track as the track is quite old and at various locations the
cake formation has already took place.

6.

Formation:
The boxing and dressing of ballast in track is required in several
locations.
At approach of track hopper (near level crossing), bushes and
plants including grasses in & around of track are found, which need
to remove and maintain the track proper. To tackle the high
8

FARAKKA
vegetation in the track, regular grass cutting to be done to improve
the visibility at L-Xings to avoid accidents
Drains:
During inspection of track the drain is required to be cleaned at
following locations
a) All cutting areas of track.
b) As there is no drains at Station yards more cross drains
has to be provided to avoid mud pumping
.

7.

Condition of Rails:
Satisfactory, Most of the locations scabbed rails are found through out
the section which need to replace.

8.

USFD testing of Rails:

The entire section of the work of USFD for the year 2013 is
completed in Jan-2014 and defective rails 19 nos replaced.
Futher USFD test for the year 2014 has been started recently in
Sept-2014.

9.

Jammed joints:
a. Almost in all the sections the Low joints are found, which needs
proper attention.
b. The Welding of rail joints need to be taken up to reduce the no.
of joints and convert the complete section in SWR section.

10.

Creep:
As the sleepers and rail renovation is in progress the creep
adjustment to be done after completion of work.
Curves :
a. Kinks were observed at various Curves.
9

FARAKKA
b. Realignment of most of curves is immediately required. Curves from
Workshop to Pathra and up to Loading Point, to be done on priority
basis.

11.

Overhauling of Track & level crossings:

a. As per last audit, the overhauling of track was not being done. This
year, approx. 20 Km track is done so far as per site. However
1/3rd of track length must be done as per IR norms.
b. All the Level crossings are renewed with PSC sleepers.

12.

Points and Crossings:

All the built up crossings with wooden sleepers are replaced by CMS
crossings with PSC sleepers. A sample point & crossing checked in the
MGR yard point no:27 B and readings are as follows.
Crossing wear-Nil, Check rail clearance at ANC: Main Line-46 mm Turn
out-45 mm. Wing rail clearance Main line-44, 45 mm, T/out 44,45 mm.
Tongue rail opening = 110 mm, Heel Divergence: LH-186 mm RH-185
mm.

The points and crossings are being inspected on 6 monthly basis as per
the records produced.

All fouling marks to be re- located according to new CMS X-ings.

All replaced CMS X-ings & points needs numbering and marking on
Motor points & T-boards also..

16. Bridges:
(a) For regular system of checking of bridges checking is being
done as per CC format.

10

FARAKKA
17. Indication/Caution board: There are no curve boards. They are to be provided as per IR
specification.:- All under mentioned points Contract has been
awarded and work is in progress.
Creep posts: Available. Numbering is required like.
Curve detail boards: Curve numbers, Versine, SE, Station No.
are not visible, needs to be rewritten on the rails of all the curves.
Bridge details (Br No., Span, Type of Bridge, HFL etc) are not
marked on most of the bridges. In some bridges, the details written
are not visible. They need to be repainted.
It is suggested that the long trees available on both sides of the
track can be used to clamp the boards at a higher elevation or they
can be painted on the tree itself.
All the missing engg. Boards to be fixed in all sections
including plant area and repainted Site informed that a work
award is under process for this work this is pending since
last audit.
All caution boards e.g. Level crossing and unauthorized level
crossing to be painted and missing boards to be re-fixed as
per IR norms.
Record Keeping:
(a) All the track maintenance records are being maintained on the
register .
(b) Gang charts are printed and implemented.
(c) Daily progress Register: Available.
d. However, only works like through packing, Slack packing is being
recorded.
e. Record of Track
maintained..

overhauling
11

(Shallow

screening)

is

being

FARAKKA
f. Curve Register: Available.
g. Points & Crossing Register: Available.
h. Creep Register: Available.
i. Level-Xing Register: Available.
j. Gang chart: Available.

ROLLING STOCK (Locomotive):

A. Details: As on 12.09.2014
Loco

Type/

No

Model

001

WDM2

H.P

2600/

Date of

Whether equipped with

Commissioning

Dynamic

Speed

Creep

Brake

Recorder

Control

9.12.1987

O.K.

O.K.

2400
002

WDM2

- do-

9.12.1987

O.K.

O.K.

003

WDM2

- do-

24.4.1987

O.K.

O.K.

004

WDM2

- do-

24.4.1986

O.K.

O.K.

005

WDM2

- do-

16.2.1985

O.K.

O.K.

006

WDM2

- do-

20.6.1990

O.K.

O.K.

12

Remarks

FARAKKA
007

WDM2

- do-

4.12.1990

O.K.

O.K.

008

WDM2

- do-

14.3.1991

009

WDM2

- do-

15.7.1991

O.K.

O.K.

010

WDM2

- do-

15.7.1991

O.K.

O.K.

011

WDM2

- do-

17.7.1995

O.K.

O.K.

012

WDM2

- do-

Oct-1989

O.K.

O.K.

014

WDM2

- do-

20.1.2000

O.K.

O.K.

015

WDG3

3100

11.11.2010

O.K.

O.K.

O.K.

016

WDG3

3100

11.11.2010

O.K.

O.K.

O.K.

017

WDG3

3100

11.11.2010

O.K

O.K

O.K

Sent to Talcher on loan (11.03.2005)

B. Percentage Average availability of Locomotives(should not be < than 85%)

Loco
No

Previous
month Aug
14

During the
year (13-14)

During the
year (12-13 )

13

During
previous year
(11-12 )

Remarks

FARAKKA
001

96.0

93.7

97.0

85.4

002

97.0

96.5

96.5

57.1

003

97.5

97.55

97.55

97.789

004

97.3

95.0

95.0

75.523

005

97.5

97.0

97.0

96.789

006

96.8

98.0

98.0

98.5

007

97.0

97.0

97.0

96.995

008

LOCO F-008 sent to Talcher Super Thermal Station on 11.03.05

009

97.0

95.6

85.5

010

96.00

96.5

98.998

011

96.00

96.0

98.596

012

96.7

97.0

98.925

014

JMP

94.0

97.982

015

98.5

97.59

98.95

016

98.0

98.5

98.94

017

99.0

98.0

98.955

Percentage Average availability of Locomotives : Year 2013-14=97.16 %

C . Specific Fuel Oil Consumption
Loco
No

Previous month
Aug14

During the
year (1213)

During previous
year (11-12)

001

Rly Rake

3.915

Rly Rake

002

5.868

5.1

4.616

003

5.4

4.25

4.634
14

Remarks

FARAKKA
004

5.832

5.723

Rly Rake

005

Rly Rake

Rly Rake

4.846

006

Rly Rake

5.012

4.978

007

5.76

5.22

4.854

008

LOCO F-008 sent to Talcher Super Thermal Station on 11.03.05

009

5.364

4.012

4.652

010

Rly Rake

3.897

4.978

011

5.508

5.687

4.939

012

5.4

4.023

4.981

014

Rly Rake

Rly Rake

Rly Rake

015

Rly Rake

Rly Rake

Rly Rake

016

Rly Rake

Rly Rake

- do -

017

Rly Rake

Rly Rake

- do -

D . Lube oil- Fuel oil ratio;

Loco
No

Previous month
Aug14

001

Nil

0.569

Nil

002

Nil

1.00

0.681

003

0.513

0.65

0.860

004

0.414

1.99

1.03

005

Nil

1.987

1.191

006

1.058

0.885

0.614

007

0.542

0.751

0.637

008

During the
year (12-13)

During previous
year (11-12)

Remarks

LOCO F-008 sent to Talcher Super Thermal Station on 11.03.05

009

0.754

0.678

0.984

010

Nil

0.621

0.703
15

FARAKKA
011

1.225

1.759

0.925

012

0.356

0.582

0.917

014

0.556

1.82

0.985

015

1.818

Nil

Nil

016

0.843

Nil

Nil

017

2.394

Nil

Nil

HY schd done, lub oil refilled

HY schd done, lub oil refilled

E.Details of Locomotives overdue for higher schedule Yearly: M-24 & above
Copy of Program of higher schedule for Year 2014-15 (Six Year Rolling Plan) is as under :
Loc Type Comm.
LAST
Last
09-10
o
Date
P.O.H
Schedule
No
001 WDM2 9.12.198 20/01/06 M-48
M18
.
7
JMP
Apr-12
Feb-08
002 - do - 9.12.198 10/ 2007 M-48
.
7
JMP
Dec-10
003 - do - 24.4.198 06/ 2009 POH
.
7
JMP
17.06.200
9
004 - do - 24.4.198 12/ 2003 M-54
.
6
JMP
18.11.200
9

10-11

M-48
Dec-10
POH
Jun 09

14.3.1991 11/ 1998

JMP

13-14

14-15

15-16

16-17

M-48
Apr-12

M-72
Dec-14

POH
Aug-16

Sp Rep
Jun-12

M-72
Jan-15

POH
Jul-16

M-24
Dec-12

M-48
Feb-15

M-72
Mar-17

M-48
Feb-11

007 - do - 4.12.199 12/ 2005 M-48

.
0
JMP
Apr-11
- do -

12-13

M-54 Recd -KH

Nov- 09 20.11.20
11

005 - do - 16.2.198 04/ 2001 POH

POH
.
5
JMP
26.09.200 Sep9
09
006 - do - 20.6.199 09/ 2005 M-48
.
0
JMP
Feb-11

008.

11-12

POH
Aug-13

M-24
Aug 15

M24
Sep-13

M-48
Sep 15

M-72
Nov-13

POH
Nov-15

M-48
Apr-11

M-72
Apr-14

POH
Aug-15

Diverted to TALCHER on
11.03.2005

009 - do - 15.7.199 11/ 2004 M-72

.
1
KGP
Jan-12
010 - do - 15.7.199 03/ 2007 M-72
.
1
JMP
Sep-12

M-72
Jan-12
M-36
Mar 09

POH
Mar-14
M-72
Sep-12

011 - do - 17.7.199 06/ 2010 S.R C.SM-54 S RJun-10

.
5
JMP
Blk
Nov- 09 (5.06.10)
Chg/5.06.

16

M-24
Jan 14

M-24
May-16
POH
Jan-15

M-24
Jan 17

M-48
Dec-14

M-72
Feb-17

FARAKKA
10

012 - do - Oct-1989 04/2012 M-54

.
JMP
21.08.200
8
014 - do - 20.1.200 POH
M-18
.
0
5.07.20 10.03.201
08
0
015 WDG3 11.11.20
10

M-54
Aug 08

POH
Apr13

M-18
Mar-10

M-24
Aug-14
M-48
Dec 13

016 - do - 11.11.20
10
017 - do - 11.11.20
10

M-48
Oct-16
M-72
Dec 15

M-24
Jun 14

M-24
Jun 16

M-24
Aug 14
M-24
Oct 14

M-24
Aug 16
M-24
Oct 16

F. System of Maintenance:
i) Departmental/Expert Agency: Expert Agency- M/S RITES.
ii) Concept of attending of different Schedule of maintenance: - i.e. based on running hrs. / Time based. :
Time based (Fortnightly, Monthly, Quarterly & Half Yearly)
iii) Specify the concept values for taking up different schedules: As per Railway norms.
G. Check Hauling power and other Loco operating parameters
Inspection of NTPC load rake No 300 Dt 27-28.08.2013 with Loco. No - 03 & 07 was done from
Lalmatia to Track hopper #2 Farakka and following observations was recorded :Rake Size: 50 wagons plus brake van
i) General health of both the loco Crews is in good condition.
(ii) Communication equipment i.e. wireless set was found in working order.
(iii) Load Meter Working order on both control stands
(iv) Speedometer Analog & Electrical speedometer available at both control stand.
(v) Fire extinguishers checked in loco-07 & 03 and found available.
(vi) Creep control device in loco was not available.
(vii) Loco hauling power was good.

FOOT PLATE INSPECTION OF LOCO NO F-006 +001

DISCRIPTION

NOTC
H1

NOTC
H2

NOTC
H3

NOTC
H4
17

NOTC
H5

NOTC
H6

Date : 10.09.2014
NOTC
NOTC
H7
H8

FARAKKA
RAKE POSITION

10

12

15

18

20

23

26

29

LCP POSITION

Max

Max

Max

Max

Max

Max

05-30

05-30

FUEL OIL PRESSURE

4.2

4.2

4.2

4.2

4.2

4.2

4.2

4.2

LUB OIL PRESSURE

3.0

4.0

4.5

4.5

5.5

5.7

6.0

6.0

BOOSTER AIR
PRESSURE
MOTOR CURRENT
(Amp)
MAX SPEED (kmph)

----

----

----

----

0.2

0.5

0.8

1.2

250

350

400

430

450

500

550

630

----

----

----

----

----

40

40

55

LOAD

54 Loaded wagons + 01 Brake van & 02 Multi Loco

BRAKE PRESSURE AT
ENGINE
BRAKE PRESSURE AT
BV
Rake no 399B

5.1

5.1

5.1

5.1

5.1

5.1

5.1

5.1

4.9

4.9

4.9

4.9

4.9

4.9

4.9

4.9

DRIVER'S NAME : L.B.Singh & M.Unus

H. Sample Check of at least 3 different schedule forms and put observations:

Monthly, Qtly and Half yearly Schedule forms checked and found OK.
I. Instances of en-route failures locomotive:

Loco

During the year

Salient Reasons & Remedial measures

No

(till date)

(attach separate sheet if required)

F-006

05.06.2013
ER-116

Failed at Kumarpur. Driver reported automatic shutdown and

Governor came out repeatedly. MCB of .FPB found defective.
Replaced and made fit on arrival at MGR.

F-006&7

09.12.2013
LR-559

Loco F007 failed at Km47, Loco not moving in forward direction but
could not rectified, asked for relief engine.

F014&00
4

29.05.2014
LR-165

Loco failed due to fuel oil pressure zero. On checking found fuel
pump motor was not working. Checked and found FPB 15Amps
circuit breaker failure.

18

FARAKKA
F007+00
1

20.08.2014
LR-343

Loading point Loco 007 failed due to heavy air leakage from inter
cooler. Relief engine sent.

F006&00
9

22.08.2014
LR-345

Loco 009 failed at 24KM Kumarpur due to huge water leakage from L8
water jumper. Sent relief engine.

J. Facilities available for in house maintenance of Locomotives for

attending PM schedule up to 6 monthly and their adequacy: Available
Check availability of following major M&P and special tools for attending PM schedules:
EOT crane 40T/10T

Available

Synchronous jacks

4 Nos available

Loco Battery charger

Available

Governor Test stand

Not in use (Repair through Railways)

Induction heater oven

Not available

Car Body filter cleaning plant

Available

Fuel injector test stand

Available

Air Brake Test stand

Available

Cylinder Head test stand

not available

Water pump test stand

not available

Air maize cleaning plant

not available

After cooler cleaning plant

not available

Mini DM Plant

not available

Creep control test stand

available

19

FARAKKA

i.

Transition test kit

available

Stationary air compressor

available

Stationary air compressor (T/H) :

available

Allied Systems Checks:

01. Whether Load Test of EOT crane and testing of lifting tools and tackles
Are being done in time or not:( date of Last test. )
2. EOT Crane 40T/10T last load test done on: 26.12.2013.
3. EOT Crane 15T last load test done on

: 20.06.2014

4. Whether procedure for handling of HSD (HSD filling arrangement for Locomotives) and
safety aspects are being followed properly or not: All procedures are being followed.
5. Whether Re-railing equipments and jacks are maintained properly and are stored in a
separate van or not. = (MFD) 17.04.2014 & (LUCAS) 28.12.2013. Regular checking for
proper functioning is done on every Wednesday.
6. Whether drainage system of Workshop is adequate and regular cleaning is being ensured.
Adequate and regular cleaning being done.
7. Whether the necessary license for HSD installation is renewed: 3x70 KL=210
KL HSD installation of NTPC-MGR is renewed up to 31/12/2014

WAGONS:
A

Approved nos of Wagons (2003)

276

(30 nos.Transferred to TSTPS)

Total population
A1

246

Population of wagon-(as on date)

231

No. of wagons Condemned:

15

Procurement plan
1) 21 Wagons( Texmaco) received at site on 17.08.2013 vide PO No 4000073900,
commissioning & PG test completed on 26.09.2013
2) 11 Wagons(BSCL) received at site on 17.08.2013 vide PO No 4000073900,
commissioning & PG test completed on 06.03.2014.
3) P O No. 4000130589 dtd. 24.05.2014 raised for 10 nos. Wagons & Due on Dec 2014
4) P O No.4000130590 dtd. 24.05.2014 raised for 08 nos. Wagons & Due on May 2015

20

FARAKKA
Intensive rake checking is done once in a month. Time taken 6 hours.
a) ROH: ROH Schedule is being done every 02 years as per Railway Standard.
b) POH: POH Schedule is being done every 06 years as per Railway Standard
D) Average Availability of Wagon (%): Not to be less than 96%.

Month

2013-14
Apr
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Jan
Feb
Mar
Average
availability

2012-13
97.8
97.58
97.9
97.4
93.9
97.8
97.19
97.74
97
97
97
97
97.1

2011-12
98.21
98.1
96.96
97.67
97.75
97.0
97.6
97.7
97.0
98.18
97.7
97.2

2010-11
96.12
97.87
97.46
98.54
96.25
97.35
98.12
97.85
98.05
97.74
95.58
95.72

95.43
93.28
94.63
95.26
94.27
96.34
96.65
98.02
96.97
96.92
97.62
96.0

97.59

97.22

95.95

4. Signaling & Telecommunications:

A. Signaling and track circuits are available at Exchange Yard, Unloading
Station and MGR Workshop only. Others - Kumarpur, Berhait, Pathra and
loading Stations no signals and track circuits are working due to rail
renewal and sleeper replacement. Trains are running on private number
exchange and communication.
B. Status of Signaling and track circuiting Systems:
Sl
no

Locations

Status
Signaling

Type

Axle Counter
/Track Circuiting
21

Availability

Remarks

FARAKKA
01

Unloading
Station &
Exchange
Yard

03

MGR W/S

03

Lalmatia
Loading
Point

AV

AV

MACLS

AV

Comprehensive
AMC and trg is
required for digital
axle counter

AV

-do-

- do -

AV

NOT
WORKING

NOT
WORKING

--

NOT
WORKING

Only point No
25A/B AV

Not available due

to rail and sleeper
renewal

04

Kumarpur

- do -

- do -

- do -

- do -

05

Berhait

- do -

- do -

- do -

- do -

06

Pathra

- do -

- do -

- do -

NOT
WORKING

Not available
due to rail and
sleeper renewal

07

Entrance
Cabin

- do -

- do -

- do -

AV

B. Adequacy and availability of Communication system:

a.

VHF base & hand held communication system: - Adequate and well
maintained.

b. DTMF System as a control phone: - Available.

C. Check & verify the instances of signals and communications failures

Signal failure registers are available.

Brief comments on Analysis and rectification Report of failures of Signals and
communications system for more than 03 hours during last 03 months.
22

FARAKKA
Signal failure register available in MGR Workshop station. Five failures
observed in a month of Aug14. Most of the failures are due to
miscreants cutting the jumpers of the track and are attending by the
available S&T staff within stipulated time. However other station signals
are not available due to Rail renewal (52kg to 60kg) & sleeper
replacement by M/s Rites. Presently 60kg block insulation fish plates
are not available (under machining). Other signaling equipment such as
battery banks, chargers, RRI, DGs are in order. Restoring of all track
circuits is required for signal availability, operation of point machines in
way side stations and safe & smooth coal transportation. Possibility of
uninterrupted electrical power supply may be explored for all the way
side MGR Stations.

Record of checking and testing status of following for last 03 months:

Sl

Equipment

Frequency

01

Testing of Motor
Points for smooth
Operation and proper
setting (with 5 mm
No-

Monthly

Status
Done
O.K.

Gauge for obstruction

test).
23

Action taken
Obstruction test carried
out at a) Exchange Yard
Point no 34 & 35 b)
MGR Workshop 21A/B
tested & found ok.

FARAKKA
02

Testing of focus of
Signal, Cleanliness of
Lenses and visibility
To Loco crew.

Monthly

OK

Signal aspects are being

replacing
by
LED.
Started
from
signal
starter 4&6 at MGR
workshop.

03

Testing of Track
Circuit:

Monthly

Within

Testing of track circuit

carried out at MGR
Workshop found OK.

04

Checking & topping

up of batteries

Weekly

Done/O.K

Done regularly

05

Testing of Generator
Set on full load

Monthly

working

Facility for full

06

Limit

Load test NA.

Lubrication of Tongue Weekly

rail, Stock rail

Done

Done regularly.

O.K.

And Slide chairs

MGR Operation:
A. Rake Size (Nos. of Wagons).
As per DPR

57

B.

Actual

53

Suggested if
any

Remarks
Maximum line capacity at all stations is
for 55 wagons only. Total available
wagons are 223 only.

NIL

Maximum Permissible Speed and Cycle Time (in Hrs-Mts).

Particular
s

As per
DPR

Actual

Reasons
24

Expected
date to

FARAKKA
Achieve
Max
Permissible

65 KMPH

30 KMPH

Strengthening of track is in
progress.

Dec14

Average
Speed

55 KMPH

20 KMPH

Strengthening of track is in
progress and speed
restrictions in some
curvature/ gradient

Dec14

Cycle Time

06 Hours
25
minutes

Average
1. Less coal feeding at
cycle time
loading point.
for last 12
2. Miscreant activity in
months=
route.
15:14Hrs.

Speed

3. Less section speed due

to
PSC
sleeper
replacement, boulder &
packing requirement.

C. Details of Speed Restrictions/Caution order for speed 30 kmph or

less:
Sl
No

Location

Type

Authorizing
Authority

From

To

Reasons

01

25-26 km

Permanent

RITES

1995

Till
date

Critical
curves

02

43-45 km

- Do -

- Do -

- Do -

- Do -

- Do -

03

68-69 km

- Do -

- Do -

- Do -

- Do -

- Do -

25

FARAKKA
D. Check List for Operational Safety:
1. Whether prescribed medical examination of the Loco Drivers and
Staff is regularly carried out in time= Yes, done in every Six month in
NTPC hospital (Records verified).
2. Whether long duty hours are defined /fixed at 12 Hrs in line with the
Railway working: Followed but due to Higher cycle time, shortage of
loco drivers the working hours of retired staff in higher side (12 to 16 hrs.)
3. Adequacy of Loco Drivers: Nos. Required/Sanctioned:- Presently 34
loco drivers are in the roll against the sanctioned strength of 48.
Immediate actions to be taken for appointment of required loco drivers. In
spite of best efforts by NTPC Farakka, retired railway staff are not joining
due to poor pay package.
Presently 29 controllers, 10 guard, 01 PWI/PWI is available against the
sanctioned strength of 36 controllers, 14 guards and 01 PWI/PWM.
4. Whether Railway drivers appointed have sufficient experience of
operating WDM2/WDG3A Locomotives Being verified during Interview
& checking Service certificate, issued by Railways.
5. Whether placement of (LV) board during day Hrs and Red Lamp (Tail
Lamp) During night/thick and foggy weather is compulsorily
followed.= Indian railway retired guard is accompanying in all moving
rakes with red & green flag, Flasher Tail lamp and tri color light. Guard is
also provided with talkie talkie for better communication with loco driver.
6. Working instructions are prepared and are acknowledged in writing
by all the Staff concerned with MGR trains operation.- Rake operating
instructions are available but required to review & modify as per present
condition.
7. Whether station-working rules are available at MGR control room
and at all Stations=Individual station working rules are available in each
station.
8. Whether the Train operational requirement of not permitting any
rake to enter the block section until and unless previous rake is
26

FARAKKA
clear the block section & clear the safe distance beyond the 1st stop
signal of the next station is being followed= Yes.
9. Whether the person granting permission through physical
verification or other means of the last Vehicle is ensuring complete
arrival/departure of the train =Brake van is attached in all rakes as last
vehicle and railway retired guard is accompanying every rake.
10.
Whether electronic breath analyzer to ascertain that the loco
crew members are not under the influence of alcohol at the time of
reporting of duty and on leaving after duty (signing ON & signing
OFF) is installed in the central control Room or the place where
they report for duty= Electronic breath analyzer is available in working
condition in MGR control room and it has been observed that random
checking is being carried out. It is to be in practice on regular basis and
proper record to be maintained.

General Observation (MGR Operation):

Most of the operation formats are filled properly at MGR control
room, Evidence checked at MGR Control Room, Kumarpur and Patra
station.
Medical Checkup of Railway retired staffs are being done after an
interval of Six Months. Records verified.
With the approval of competent authority, Loco drivers and
Controllers are continued up to maximum of 67 years due to non
availability.

27

FARAKKA
All intermediate stations are also equipped with Crank Handle, Signal
Torch / Hand flags & Track layout diagram evidence checked at
Kumarpur & Pathra station during visit.
Foot plating by Operation and track staff has been carried out on
regular basis. The frequency of foot plate and way side station
inspection should be maintained as per norms and caution to be
issued to the crew as per comments of foot plate inspection for safe
movement of coal rakes.
Fire extinguishers available in MGR control room, Wayside Stations
are in filled condition.
All the rakes are equipped with Tool Box (Spanner, C clamp, Skids,
Break hose pipe, knuckle & Fish Plate sets etc) along with Signal
Torch / Hand flags and fire Extinguishers.
Regular safety counseling with loco drivers being carried out by MGR
staff and RITES.

Movement order issued to loco drivers by MGR control room is filled

properly and being acknowledged by loco driver.
Intensive checking of the rake at Inspection line are being carrying
out as per schedule. Brake power testing to be witnessed by
operation and being signed the protocol. Presently being signed by
Rites only.
28

FARAKKA
First aid box with all the medicines are be available at MGR control
room and other wayside stations.
For ensuring of the safe movement of the rake during passing of the
rake from the intermediate stations, loaded/empty rakes are checked
by the Station controller for hot axle, hanging parts from loco &
wagons, any abnormal sound coming from loco/wagon.
NTPC Weigh Bridge is working properly & weighment of All the IR
rakes (Load & Empty) is recorded. CC camera is also provided and in
working condition

Schedule for MGR Foot Plate Inspection

(Based on Enquiry committee recommendation)
Inspection including foot plates and monitoring of installations/ equipments,
staffs should be carried out and must programmed for each senior executives
as under.
MGR executive

Minimum one per week

MGR I/C

Minimum Once per fortnight

Safety Officer

Minimum Once per fortnight

O&M Head

Once per Month

GM

Half yearly along with all

Concerned Executives

Check the Records of unusual Occurrences/Derailments causing disruption of

traffic are maintained properly.
Maintained in Register and in soft copy.
29

FARAKKA
PROFORMA FOR RECORDS OF DERAILMENTS/ ACCIDENTS
Sl Date & Time
No
Of
Occurrences

Date &
Time
Of
Restorati
on

01 02.08.2014

02.08.14

01:50 Hrs

02 02.08.2014

Reason Of
Derailment/
Accident

At
Track boulder
Hopper
#2
04:20Hrs
MGR wagon
No 2001 FKK
03, one trolley
derailed

22:30hrs

20:10 Hrs

03 03.08.2014
15:30hrs

Brief
Description of
Accident/
Derailment

03.08.14
17:30hrs

Losses/
Damage
s
With
approx
Cost

At
Track
Hopper #2 IR hit
with DC ch
wagon
No boulder
increas
73141355971/
ed
BOBRn/SECR
one
trolley
derailed

At
Track hit
with DC ch
Hopper #2 IR boulder
increas
wagon
No
ed
72110602320/
BOBRn/SECR
one
trolley
derailed

30

Enquiry
Committee
Recommenda
tions

FARAKKA
04 04.08.2014
22:00hrs

05.08.14
13:30hrs

Side collision Fouling was betn

wagon not cleared
No
88FKK
078
and
2001FKK 03
during
placement of
empty rake No
306
in
inspection line

05 05.08.2014
06:00hrs

05.08.14
15:30hrs

Wagon
No Fouling was
2001 FKK 03 not cleared
capsized near
inspection line

06 11.08.2014
00:15hrs

11.08.14
13:50hrs

IR
wagon Point
SCR BOBRn route
73091340881
derailed
at
point No 33 in
exchange
Yard

07 18.08.2014
00:15hrs

18.08.14
02:45hrs

IR
wagon Motor point DC ch
BOXn
SE- not
set increas
12477 SECR properly
ed
derailed
at
point No 34 in
exchange
Yard

31

two DC ch
increas
ed

FARAKKA
Observations & Recommendations
Track:
1) By replacing of CST-9/wooden sleepers with PSC sleepers, track condition got
improved, however wheel burns are observed at many places of through out the
section. Necessary action to reduce further wheel burns of rails and replacement of
rails may be taken up: It is observed that M/s RITES has already replaced 16 Km
length of 52 Kg rails by 60 kg rails.
2)
It is observed that all built up X-ing turn outs with wooden sleepers have
been replaced by 60 Kg CMS X-ing turn outs with PSC sleepers. Only 3 nos are
remaining for changing which is in progress.
3) on bridges deep screening of ballast to be done for easy drainage and
shortage of ballast to be recouped.
4)
In cutting areas the damaged drains to be repaired and J type
drains are to be provided wherever the pucca drains are not existing.

5).

At present, existing track from inside plant area to loading point

(Lalmatia) including yard lines are having partially short welded
rails (SWR) section of track.
In the last year 2013 Technical audit team recommended that
all track section including yard lines are required to convert in
SWR section using AT welding of rails by which a smooth
running may be ensured and also minimize the sabotage at track.
A Purchase requisition has been raised by site vide PR
no:200042063 dated 01.06.2013. Price bid has been opened
and under negotiation due to high rate on single quotation.

6).

As per recommendations of the last audit, 05 PWIs have been

recruited against 06 PWIs balance one PWI also may be
recruited to enhance the quality of track maintenance work
and safety of the rolling stock movement.
32

FARAKKA
7).

It is observed that ballast deficiency still existing in the track after

spreading of 32500 cu.m against the P.O Qty of 35000 Cu.m.
Further 50,000 Cu.m of ballast to be procured to recoup the need
since the track ballast got scanty from recent renovation of CST-9
by PSC sleepers.

8) It is observed that the drain cleaning which is in progress to be

completed in the cutting areas.
9) A Rail Road vehicle can be procured by site for ease of track
inspection, track material transportation and various other uses as there is
no road connectivity all along the track in FSTPS MGR- Site informed that it
is proposed for Budget in 2015-16 as this does not come under MBOA.

10)

11)

At Km 64/450 to 64/900 km the existing guard rails are with

wooden & normal track sleepers may be replaced by PSC Guard
rail sleepers for safety of rolling stock and the state Govt.
Quarters are at ground level of the high bank .
Possibility for direct linking of T/H-II with Ex. Yard for IR rake handling
has been studied by RITES Expert from RPO Kolkata & Opined that the
linking is not feasible technically due to space constraint..

ROLLING STOCKS

All the records of Loco maintenance are very well maintained. All schedules are followed as per
Railway norms.

For replacement of Traction Motor pinion, Bearings etc suitable Induction Heater is not available. PO
placed vide PO NO: 4000132919 dated 07.09.14 complied..

PM schedule forms for WDM2 & WDG3A are to be made separately as per guideline. It is
under Progress

After intensive checking of Rake, it is proposed to reverse the direction of movement to reduce wear of
wagon wheels and uniform wear pattern of all wheels. Done for around 7 to 8 times

Around 35 wheel sets are going to be condemned in the next one year and 91 in next two years.
Immediate procurement action for minimum 125 wheel sets to be indented by site.
33

FARAKKA

As per RDSO guidelines, to reduce the repeated failure of Traction Motor, PM schedule to be
modified suitably. 9 nos of traction motors which under breakdown going for repair to Jamalpur.
Follow up action is to be done.

Following spares to be procured for Locos immediately for smooth running of locos
4)
5)
6)
7)

Roof Mounted BKBL Part No:DR1/GMH/03- 1no

Aux-Exciter Type: AG3101AY-01 nos 01 Nos.
Grid Resistance Without Tap,DR1 part no DR1/GMH/02A
Grid Resistance WithTap,DR1 part no DR1/GMH/02

8) Carbon Brush for

Traction Alternator HM6 Morgan
Aux-Exct.
EG251 Morgan
BKBL
EG8067
It has been observed that following locomotives having Hollow Tyre.
Understood that MGR has taken action for redisking the same at Jamalpur.
Follow-up to be done as early as possible
Loco # F002 Trade Wear 7 mm
Loco # F007 Trade Wear 7 mm
Loco # F010 Trade Wear 7 mm
Loco # F011 Trade Wear 7.5 mm

Handling of HSD is to be reviewed for accountability. Loco fuelling to be witnessed by concern

NTPC representative.

Central Stores inspection to be done by jointly by NTPC/MGR/Maintenance executive & rites at

least twice in a month for effective utilization of loco & wagon inventory.

House Keeping in MGR workshop is not up to the benchmark.Corgated GI sheets to be replaced

at so many places to avoid rainwater entry & for safe working of MGR machines, equipment &
personnel.

Maintenance Contract is required for microprocessor (Make M/S Medha Servo drives PVT Ltd)

Synchronous Jacks to be overhauled

34

FARAKKA

Circuit breaker test bench & traction motor no load test bench to be procured immediately for
checking of healthiness of circuit breaker & Traction motor

Luboil, water & flaw test of axles are not being done through chemistry. Same to be ensured on
regular basis.

Expertise of traction motor, Governor & trouble shooting personnel are to be deployed
immediately by M/S Rites for smooth running of locos.

S&T:
1.
2.

3.
4.

5.
6.

7.

8.

Compliance report of the previous Technical Audit report not prepared,

however most of the points are complied.
Maintenance of track Circuit, Batteries, Point Machines, Signals and S&T
Equipments are being done as per schedule in available area and records
are also updated, Ballast resistance and Rail resistance also being carried
out.
Some of the Relays in all stations not sealed, to be sealed properly as per
railway norms. Relay failure / replacement register to be maintained.
The earth resistance is also not being checked regularly. All earth pit of MGR
system should be tested at least twice a year and recorded the values. The
value also needs to be painted on the pits.
Possibility of Power supply connection from state electricity Board in all the
stations & Solar Power may be explored.
It is recommended that more no of Railway retired ESMs and Signal
Inspectors may be appointed similar to Rly retired loco Drivers for better
supervision and maintenance.
Sufficient technical documents, drawings etc shall be made available for
newly commissioned signaling and Digital Axle counters. Training for
Operation & maintenance may also be arranged.
Awareness Alarm / Theft Alarm may be provided in unmanned level crossing
and other required location wherever track circuits are available.

35

FARAKKA
MGR Operation
o It was observed that, Token less block instruments are not working.
TBI is to be replaced urgently to avoid unsafe movement. Total
operation movement is being done by exchanging private number and
on communication, which is not safe. Hence Signals must be
available in all the stations.
o Average unloading time is increasing due to huge quantity of stone
intake through Rly rakes. Though stones are breaking & removing by
Stone Breaker & JCB in Track Hoppers, Huge amount of Boulders are
still lying at track hopper which increases unloading time. Practice is
to be made that before placing loaded rake, track hopper walk way
and Grizzly is to be cleared to avoid derailment and timely unloading
of rakes.
o It was observed that, most of the derailments are due to obstruction
of boulders in track hopper area. To minimize the derailments regular
cleaning of boulders at track hopper and wagon tippler area to be
done.
o Availability of retired railway staff is less against the sanctioned
strength. Early action to be taken to recruits the shortfall.
o In WDM2 locomotives no vigilance control devices are provided, it is
suggested to provide in all WDM2 locomotives.
o Periodic Training / Awareness / Feedback session may be planned
preferably in shift general with all MGR staff including loco drivers at
least once in a month with each shift group for safe and smooth
operation of coal rake.
o

It is recommendate to use Breath Analyzer regularly and maintain the

record.
36

FARAKKA
o CSR activities being organized by MGR is appreciable.
o Coal Co-ordination documentation is up to date for domestic as well
as imported coal.

The MGR team of FSTPP is very co-operative with positive approach. The
entire MGR team was fully involved in the audit and discussions and
shown eagerness to implement various suggestions of audit team.

The report is put up for kind perusal of competent authority.

(M.V.Krishnan)
DGM(MGR)VSTPP

(C.S.Tiwari)

(P.Venkatramaiah)

DGM(MGR) KSTPP

(A.Chatterjee)
AGM(MGR)FSTPP

Sr.M (MGR) RSTPS

(B.K.Jha)
AGM(MGR)FSTPP

37

(M.M.Manzer)
Manager(ER-I HQ)

(R.K.Sinha)
AGM(MGR)FSTPP

FARAKKA

38