It has been estimated by Work Study that rehabilitation work content is nearly 4 times that of normal POH. Normal POH does not include major corrosion repairs and takes about 2500 man-hours. Mid-life rehabilitation includes heavy corrosion repair and complete refurbishing which takes about 10000 man hours (all items of POH are, in any case, covered). At present this Workshop is capable of undertaking any type of ICF coach and BEML coach with ICF Bogies.
The underlying principle of MLR is to give 'As New' condition to the coach at its mid life i.e. when it is 12-15 years of age. Unlike in POH, the coach is completely stripped, heavy corroded areas attended to, Fibre Glass Tissue re-laid/re-painted, necessary modifications carried out and new furnishing is provided. It can be seen that while corrosion repair is minimal attended to, during POH, in MLR it is completely attended to.
Functioning of various Sections/Sequence of Operations:
Paint Removal: Incoming coaches are subjected to paint removal by Grit Blasting.
Coach Lifting Shop: Coaches are lifted to remove bogies for repairs, and dummy bogies are provided for internal movement within the workshop. Examination and repair of under-frame including centre pivot and side bearers are done in this shop.
Stripping Shop: Internal components and fittings are stripped off to get bare shell for corrosion repairs. Wall panels and flooring is removed. Cutting of body side panels by air plasma cutting is done in this shop.
Carpentry Shop: All internal mechanical fittings and furnishings, including berths and seats and water tanks are repaired.
Electrical Train Lighting Shop: All electrical fittings of coach are overhauled and tested prior to re-fitment.
Body Repair Shop: The entire coach body including structural members are subjected to inspection and replacement of corroded members giving necessary anti-corrosive treatment to the components. RSP modifications including provision of UIC Vestibules is also done in this shop.
Paint Shop: The coach shell is given a new look by complete painting (A-Schedule is undertaken). Lettering work on exterior as well as coach interior is done by screen printing process. The work of laying of FRP tissue on the trough floor is also done in this shop. Air-brake retro fitment work is done in this shop.
Furnishing Shop: All passenger amenities fittings and internal components (both mechanical and electrical) in the coach are replaced/refitted. The work of PVC flooring and testing of plumbing in lavatories done in this shop.
Bogie & Wheel Shop: The running and brake gear provided in bogies are completely stripped, cleaned, inspected and refitted/replaced. The bogie frames are shot blasted. Bogies are modified and provided with brake gearing for bogie-mounted air-brake system.
(Machine shop/Wheel shop and Roller Bearing sections are attached to the Bogie shop.)
Final Shop: The coach body is lowered on overhauled bogies. Final adjustments and tests/inspection of out-going coaches including NTXR examination is undertaken in the final shop, which has pit inspection facility.
Millwright & Transport shop: Attention to all machinery and plant, lifting equipments, traversers and transport vehicle is being given by Millwright shop.
Electrical Repair shop: All repairs from electrical side to machines, plant and equipments is being given by electrical shop.
Shell Component shop: Components required for fitment in the coach shell are being manufactured from raw material (mainly corrosion resistance steel). It is a feeder shop for the body repair shop.
Laboratory: All tests including the Ultrasonic and Magnaflux testing of axles, springs, block hangers & bolster suspension hangers and die-penetrant testing of roller bearings are undertaken.