Production and Maintenance of LHB Coaches in Indian
Production and Maintenance of LHB Coaches in Indian Railways
2.1 Introduction
Indian Railways have been transporting passenger traffic mainly through
conventional coaches of ICF design. These coaches are manufactured at Integral
Coach Factory, Perambur (ICF) and Rail Coach Factory, Kapurthala (RCF). A
limited number of these coaches are being manufactured at BEML (Bharat Earth
Movers Limited)/ Bangalore.
The ICF type of coaches have limitations in terms of speed potential, heavy
corrosion, poor riding comfort and wearing of parts in the under gear. To overcome
these limitations, Indian Railways entered into Transfer of Technology (ToT)
contract with M/s ALSTOM LHB/Germany for production of LHB36 design stainless
steel coaches. Accordingly, their inception and mass production in Railways was
started in 2002. First LHB coach was introduced in Indian Railways network in
December 2003.
LHB coaches are far superior with respect to passenger comfort, safety, speed,
corrosion, maintenance and aesthetics than ICF coaches. These coaches are also
longer as compared to ICF design resulting into more carrying capacity. The
benefits from these types of coaches include:
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Linke Hoffman Busch coaches
Figure 2.1: ICF Conventional coach and LHB coachReport No. 2 of 2020
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Chapter 2 Production and Maintenance of LHB
Coaches in Indian Railways
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Better Speed Potential – Maximum operating speed of LHB coaches is 160
kmph (tested upto 180 kmph) as compared to maximum speed of 140 kmph in
ICF coaches. This can increase the availability of path.
Higher carrying capacity – These coaches are about two meters longer than
ICF coaches. With this extra length two additional rows of chairs in chair cars or
one additional bay in sleeper coaches can be accommodated. An AC III Tier
coach of LHB design can accommodate 72 passengers as compared to 64 in
ICF type. This increases revenue earning in each run.
Better pay to tare ratio37 – The weight of LHB coach is lesser as compared to
ICF design coaches, leading to lower hauling cost.
Low corrosion – Stainless Steel shell eliminates corrosion of LHB coaches.
Low Maintenance leading to improved availability – LHB coaches requires
less maintenance than that of ICF coaches. Periodical overhauling of LHB
coach is done in every 36 months in comparison to 18 months in respect of ICF
coach. This reduces the maintenance cost. Disc brakes are provided for
efficient braking and lesser maintenance also.
Aesthetically superior interiors – LHB coaches have interiors with FRP
panels38 for side wall and roof. They can be removed easily for maintenance,
resist water seepage and are wear resistant.
Most importantly, LHB coach offers better passenger safety due to
use of fire retardant materials for furnishing,
provision of four emergency openable windows for faster passenger evacuation,
and
vertically interlocked Centre Buffer Couplers with anti-climbing features that
prevents the coaches to capsize in case of a derailment.
37
Pay-to-tare ratio is the total payload divided by dead weight of a rolling stock. Tare weight is the
weight of the coach without any passenger or luggage on it, that is, without any 'load'. Payload is
the maximum amount of weight it can sustain apart from its own weight. LHB coaches weigh
approximately 10 per cent less than corresponding conventional coaches resulting in saving in
haulage cost.
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Glass Fiber Reinforced Plastic panels are used for interiors of LHB coaches.
Audit objectives:
Whether the production of LHB coaches was adequate to meet the
requirement of conversion of ICF conventional rakes.
Whether the facilities available in coaching depots and workshops of IR were
adequate for maintenance of LHB coaches.
Audit findings
2.2 Recommendation of High Level Safety Review Committee for use of LHB
coaches
The High Level Safety Review Committee (HLSRC) had analyzed (February 2012)
the casualties of passengers in train collisions and derailments, in addition to other
issues. They opined that ICF design passenger coaches were not safe at
operational speeds of 100-120 kmph with trailing loads of 20-24 coaches. They
strongly recommended complete switching over to the manufacture of LHB design
coaches and immediate stopping of manufacture of ICF design coaches. For usage
of the existing large fleet of ICF design coaches, they recommended to relegate
these coaches in trains having composition of lesser than 18 coaches and with
lesser speeds. The XIIth Five Year Plan also envisaged complete switch over to
new manufacture of only LHB design coaches by the end of 2017.
Audit observed that Indian Railways stopped production of ICF coaches only with
effect from April 2018. Over the last five years the pace of production of LHB
coaches has increased. However, the share of LHB coaches to the total coaches
of Indian Railways produced during 2013-14 to 2017-18 was about 30 per cent.
HLSRC had recommended relegating ICF coaches for running trains with less than
18 coaches and with lesser speeds. Audit scrutiny of records of operating
department of Zonal Railways revealed that as of March 2018, 903 rakes of ICF
conventional coaches were still being run for trains with 18 or more coaches.
Further, the trains had a capacity to run at a maximum speed of 100 kmph or more.
Only 252 rakes were running with LHB coaches as of March 2018. Details are
shown in Annexure 2.1.
Running of rakes with 18 or more conventional coaches at high speed
exposes the passengers to the risk of unsafe journey.
2.3
Production of LHB coaches
Indian Railways have three passenger coach manufacturing units viz., Integral
Coach Factory Perambur (ICF), Rail Coach Factory Kapurthala (RCF) and Modern
Coach Factory Raebareli (MCF). ICF and RCF are manufacturing both
conventional and LHB coaches. MCF was set up in April 201139 to produce LHB
coaches only. As of March 2018, production of conventional coaches in ICF and
RCF during last five years was more than three times of production of LHB
coaches even after 15 years of introduction of LHB coaches. In addition, Railways
also planned to set up new production units of LHB coaches at Kanchrapara and
Singur. Proposals for Kanchrapara were sanctioned in the budget of 2009-10 and
proposal for Singur was yet to be approved. However, no production plan was
programmed from two units (Kanchrapara and Singur) till March 2018.
Audit analyzed the installed capacity of production of ICF and LHB passenger
coaches vis-à-vis the production in last five years.
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MCF Raebareli has been declared as a production Unit by Ministry of Railways with effect from 1
July 2014 vide Railway Board’s notification dated 30 June 2014.
Audit observed that MCF could not achieve the production as targeted in the
production programme since its inception. The acquisition plan from MCF was
2,800 coaches during the Plan period (2013-14 to 2017-18). But, the production
program was set only for 2,135 coaches. However, during 2013-14 to 2017-18, it
could actually produce only 1,842 coaches. Audit noticed that
Important plant and machinery viz, Integrated Shell Assemblies and Assembly
Line were yet to be commissioned as of March 2018. These were installed
earlier between June and November 2015,
Other machines40
, procured in February 2014 and December 2012 were
rejected in July 2017 and September 2017 due to non-compliance of the
productivity standards.
In addition, CNC laser cutting and welding machines, CNC laser cutting
machines, CNC Plasma Profile Cutting machines remained either on breakdown
40
viz., Bogie Fabrication Line, Slitter-cum-cut-to-length combination line machine.
Maintenance of LHB coaches
(a)
Maintenance facilities at coaching depots
There is need to keep necessary spare items (stock and non-stock) and trained
manpower in the coaching depots for maintenance of LHB coaches. Indian
Railways have 176 coaching depots. Audit test checked the records of 53 coaching
depots to analyse the adequacy of maintenance of LHB coaches. Audit noticed
that
Infrastructure facilities were adequate for maintenance of LHB coaches in 34
coaching depots.
There were lack of adequate facilities for maintenance of LHB coaches in 19
coaching depots out of which in 14 coaching depots, the required infrastructure
facilities have not been proposed.
Spare items for maintenance of LHB coaches were not being properly
maintained in 12 coaching depots. These were made available from other
depots/workshops.
There was lack of trained manpower for maintenance of LHB coaches in seven
coaching depots.
Details are shown in Annexure 2.4.
During Exit Conference (6 May 2019) Railway Board stated that Railways have
identified constraints and problems facing in maintenance of LHB coaches in
coaching depots. All efforts were being made to address the constraints for smooth
maintenance of LHB coaches.
In reply, Railway Board stated (20 June 2019) that instructions exist regarding
adequate planning for maintenance of LHB coaches. They further stated that Zonal
Railways were providing maintenance spares, staff training needs etc. at all
coaching depots.
Railway Board did not respond specifically to deficiencies noticed in 53 coaching
depots reviewed by Audit. Railway Board need to analyse the deficiencies that
exist in the coaching depots for maintenance of LHB coaches. Report No. 2 of 2020
(Railways)
Chapter 2 Production and Maintenance of LHB
Coaches in Indian Railways
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(b)
Maintenance facilities of LHB coaches at Workshops
With the induction of LHB coaches in the services, workshops should have also the
facility for Periodic Overhaul/ Intermediate Overhaul (POH/IOH)
43 of LHB coaches
including regular maintenance. The structure and composition of LHB coaches are
different from that of conventional coaches. As such, specific
infrastructure/facilities/M&P are required for POH/IOH of LHB coaches. Audit
reviewed the status of availability of infrastructure in workshops over Indian
Railways. Audit analyzed whether the infrastructure was adequate for POH/IOH
and other maintenance activities of LHB coaches. Zonal Railway wise Audit
findings are discussed below:
Central Railway – The work of creation of facilities for maintenance of LHB
coaches in Parel workshop was sanctioned in 2017-18 at a cost of ` 88.14 crore.
Later, Railway Board gave (October 2017) in-principle approval for the closing of
Parel workshop for provision of passenger terminal facility. The facility for POH of
LHB coaches was not available in Central Railway. Accordingly, CR proposed
(January 2018) the work of setting up of POH workshop for 100 LHB coaches per
month in Nagpur Division. Railway Board’s sanction for the same was yet to be
received. At present, LHB coaches are sent to Lower Parel Workshop of WR.
In reply, Railway Board stated (20 June 2019) that it was decided to create facilities
for maintenance of LHB coaches in CR’s Matunga Workshop, Mumbai. They also
stated that proposal for work of setting up of POH workshops in Nagpur division
would be sanctioned after presentation of regular budget of 2019-20. However, till
the creation of maintenance facilities at Matunga, LHB coaches continued to be
sent to Lower Parel Workshop which would increase the burden of existing
Workshop.
Eastern Railway – Liluah Workshop is the only carriage maintenance workshop
where POH of LHB coaches are undertaken. Only infrastructure development work
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Intermediate overhauling (IOH) is done every nine months in the nominated Coaching Depots
and Periodical Overhauling (POH) is done every 18 months in Workshops. During IOH & POH,
the coaches are critically examined for corrosion, structural damage, stability and ensuring the
fitness of the coaches for its safe run. The coaches are being put into service only after ensuring
compliance with maintenance standards. Report No. 2 of 2020
(Railways)
Chapter 2 Production and Maintenance of LHB
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(facilities for overhauling of new generation coaches including 26 m long coaches)
was completed in December 2015. Works of modernization of workshop, included
creation of infrastructure for 24 m long LHB coaches was sanctioned in 2008-09.
Physical progress of these works was only 65 per cent. Another work viz., capacity
augmentation work for maintenance of 30 LHB coaches per month was sanctioned
in 2012-13. The physical progress of this work was only 29 per cent as of
November 2018. In reply, Railway Board stated (20 June 2019) that modernization
and capacity augmentation works at Liluah were being closely monitored. The
target of POH of LHB coaches has been enhanced to 562 coaches this year from
372 coaches last year. They further stated that another work for creation of facility
for POH of LHB coaches has been sanctioned at ER’s Kanchrapara workshop.
Railways need to complete the augmentation work of existing workshop and
creation of facilities in new workshops within a prescribed time frame to cater to the
existing requirement of POH of LHB coaches. This would also ease the burden of
existing Liluah Workshop.
East Central Railway - Carriage Repair Workshop/ Harnaut is the only workshop
in ECR. The works of developing infrastructure for POH of wheel set for LHB
coaches and developing facility for IOH of LHB and ICF bogies were sanctioned in
2017-18 and 2018-19 respectively. However, no significant progress was noted as
of September 2018. At present, the Workshop is carrying out POH of only non-AC
conventional coaches. This zone has holding of 654 LHB coaches and for POH,
LHB coaches were being sent to Liluah Workshop of ER and Gorakhpur Workshop
of NER.
In reply, Railway Board stated (20 June 2019) that ECR was being followed to get
the execution of augmentation works of Harnaut workshop expedited. Railway
Board needs to keep monitoring for early completion of work. This would avoid
operating expenditure on empty haulage of LHB coaches for POH to Liluah and
Gorakhpur Workshops.
Northeast Frontier Railway –There are two workshops at New Bongaigaon and
Dibrugarh Town in NFR. The facilities for POH of LHB coaches did not exist in
these workshops. The work related to facilities for POH of LHB coaches was
sanctioned in 2013-14 in Dibrugarh workshop. The work was still under progress Report No. 2 of 2020
(Railways)
Chapter 2 Production and Maintenance of LHB
Coaches in Indian Railways
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as of August 2018. In New Bongaigaon Workshop, the work of improvement of
infrastructure for creation of Refurbishing of LHB coaches was sanctioned in 2018-
19. The work was at tendering stage. In reply, Railway Board stated (20 June
2019) that the works in Dibrugarh workshop was in advance stage with 95 per cent
physical progress as of April 2019. They further stated that work for setting up of
new Bongaigaon workshop was started in December 2018. Railway needs to
expedite completion of these works at the earliest.
Northern Railway – NR has two workshops viz., Jagadhari and Alambagh. The
number of holding of LHB Coaches has been increased from 514 in 2012 to 1,463
in 2018. Accordingly, infrastructure of Plant and Machinery has been augmented in
Jagadhari workshop to increase the capacity of POH of LHB Coaches from 20 to
35 coaches per month. However, important machines like Shot/Sand Blasting Plant
required for Bogie Frame and Components, Bogie load testing machine and Rail
cum-road vehicle for shunting have not been provided. The Alambagh workshop
does not have the facility and infrastructure for maintaining LHB coaches.
In reply, Railway Board stated (20 June 2019) that in addition to the existing two
workshops, another workshop has been sanctioned at Sonipat for POH and
refurbishment of LHB coaches. They further stated that facilities to cater POH of
LHB coaches have been developed at Jagadhari Workshop. However, no mention
was made about creation of maintenance facilities for LHB coaches at Alambagh
Workshop.
North Western Railway – NWR has two workshops viz. Ajmer and Jodhpur. In
Ajmer workshop, there was shortage of one hydraulic material carrying and lifting
system and one single car testing for air brake system (Fixed). This hampered the
maintenance of LHB coaches as per plan. Further, POH facility of LHB coaches is
not available in Jodhpur workshop. In reply, Railway Board stated (20 June 2019)
that facilities have been developed at Ajmer workshop. In the current year target of
POH of 190 coaches has been given in comparison to target of 112 coaches last
year. However, they have not responded on the non-availability of facilities in
Jodhpur workshop.
South Central Railway - The POH facilities for LHB stock exist only in Lallaguda
workshop. All the LHB stock from all the divisions of the zone are being sent to this Report No. 2 of 2020
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Chapter 2 Production and Maintenance of LHB
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workshop for POH. The work for augmentation of Carriage Repair Shop, Tirupathi
for POH of LHB coaches was sanctioned in 2017-18. However, the work could be
started only in November 2018.In reply, Railway Board stated (20 June 2019) that
the augmentation work at Tirupathi was under progress and a target of 55 coaches
has been given for the current year. Railways need to expedite this work to
enhance the POH of LHB coaches.
South Eastern Railway – There is only one workshop in SER at Kharagpur. No
project in connection with augmentation of capacity of the workshop was taken up
during last five years. However, a work was proposed in 2017-18 for development
of infrastructure, Plant and machineries required for POH/IOH/Maintenance of LHB
coaches, However, the same was yet to be sanctioned (November 2018). In reply,
Railway Board stated (20 June 2019) that the work has been approved at a cost of
` 29.60 crore. A target of POH of 48 coaches has been given for the current year.
Railways need to expedite this work to enhance the POH of LHB coaches.
Southern Railway – POH of LHB coaches of SR is being carried out in Carriage
Works/Perambur. Further, a work related to shed for POH of 300 to 400 LHB
coaches per year was sanctioned in 2016-17. The work was to be executed by
Construction Organisation of SWR. This was later assigned to SR in August 2018.
The work was still in its initial stage. No infrastructure facility for the same was
created at Central Workshop/ Golden Rock (GOC) of SR. A work “GOC workshop
– POH facilities for maintenance of LHB coaches” has been recently sanctioned by
Railway Board in August 2018. In reply, Railway Board stated (20 June 2019) that
the construction activities as well as procurement of M&P were in progress and
was closely monitored. Railways need to expedite this work to enhance the POH of
LHB coaches.
South Western Railway – No specific infrastructural works were taken up for
maintenance of LHB coaches. The facilities existed such as sick lines44
, which are
capable for maintenance of LHB coaches. Further, a work of ‘Augmentation of
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Sick line is the workshop for the major and periodical maintenance of the coaches. It consists of
modern facilities like pit for working under frame and crane for separation of coach & bogie for
repair of all type of defects. Sick line is generally provided in the vicinity of the coaching depots and
is provided with requisite machinery and plants including facilities for lifting of coaches.”Report No. 2 of 2020
(Railways)
Chapter 2 Production and Maintenance of LHB
Coaches in Indian Railways
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POH Capacity of Mysore Workshop in Ashokpuram’ was sanctioned in 2016 the
contract for which could be awarded only in June 2018. The work was in its initial
stage. In reply, Railway Board stated (20 June 2019) that works have been
undertaken for creation of facilities for POH of LHB coaches in both Mysore and
Hubli workshops. However, it was not indicated that by when these works would be
completed. Railway needs to expedite these works to cater to the increasing
demand of POH of LHB coaches.
Western Railway – The POH facilities of LHB coaches exist in Lower Parel
workshop. Further, a work of capacity augmentation of POH of LHB coaches from
15 to 30 coaches per month was sanctioned in 2012-13 for Lower Parel Workshop.
The work was to be completed by March 2015. After lapse of six years, civil works
like construction of Pit line and service building works could not be completed (31
January 2019). Further, provision of electric fittings and power supply were in
tender stage. In reply, Railway Board stated (20 June 2019) that the work was at
an advance stage with 77 per cent physical progress and expected to be
completed during 2019-20. Railways need to expedite this work to enhance the
POH of LHB coaches.
South East Central Railway – None of the Workshops in SECR have the facility
for POH of LHB coaches. LHB coaches are sent to workshops of other Zonal
Railways45 for maintenance. These are located at a distance of 512 to 1403 kms
from Bilaspur Coaching Depot. In reply, Railway Board stated (20 June 2019) that
coach POH facilities were being developed at Motibagh workshops in Nagpur.
Railways need to expedite this work to enhance the POH of LHB coaches.
West Central Railway – None of the Workshops in WCR have the facility for POH
of LHB coaches. For this purpose, Ajmer and Jodhpur workshop of NWR have
been nominated. These workshops are at a distance of 899 kms and 1,048 kms
respectively from Jabalpur Depot. In reply, Railway Board stated (20 June 2019)
that a proposal has been received for creating LHB coach POH facilities at the
existing Coach Rehabilitation Workshop at Bhopal and it is under consideration.
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Perambur Workshop (SR), Kharagpur Workshop (SER) and Mancheswar Workshop (ECoR) -
located at 1403 Km, 610 Km and 512 Km respectively from Bilaspur Coaching DepotReport No. 2 of 2020
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Chapter 2 Production and Maintenance of LHB
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Railway needs to expedite this work to avoid empty haulage of LHB coaches to
other workshops.
North Central Railway - There is no workshop for maintenance of LHB coaches in
NCR. For POH, LHB coaches are sent to Ajmer Workshop of NWR from Allahabad
and Kanpur coaching depots. This workshop is at a distance of 627 kms and 823
kms from Allahabad and Kanpur coaching depots respectively. In reply, Railway
Board stated (20 June 2019) that coach POH facilities are being developed at
Jhansi workshop. Railway needs to expedite this work to avoid empty haulage of
LHB coaches to other workshops.
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