AUTOMATIC COACH WASHING PLANT (ACWP):

Automatic Coach Washing Plant (ACWP) is used for exterior, roof & under carriage cleaning with high pressure cleaning jets and with vertical and horizontal rotating brushing unit.

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Need & Purpose for installation of Automatic Coach Washing Plant:

• Washing & Cleaning of coaches is one of the though & critical jobs to be carried during train examination.
• The rakes of these trains are examined & maintained at C&W Depot.
• During examination of these rakes, internal & external cleaning & washing of coaches is being carried out.
• It is observed & studied that oily & sticky smoke emitted by Diesel Locos especially in tunnels result in sticky soot and stains being formed on the coaches thus resulting in a real problem of cleanliness of the
coaches and this has attracted public criticism also.
• As the staff is limited, the desired level of cleanliness cannot be done satisfactorily by conventional method within limited time period.
• To overcome the above problem of coach cleanliness, a method of external cleaning of coaches by high-pressure water jet pump was adopted.
• Eight powered nylon brushes were provided in this washing plant for the purpose of rubbing of soap solution & cleaning of dirt on external surface of coaches.
• In addition to horizontal nylon brushes, 2 Coir brush fixtures were developed and fitted in plant.
• These coir brushes were static (non-rotating type) and fixed in one position for the purpose of even application & rubbing of soap solution on surface of coach, thereby sticky particles of soot and dirt get loosened and removed. But this coir brush could not touch and clean the area near window-sills, upper and lower portions of coach since upper portion of coir brush was obstructed by coach indication lamp,
indication board, destination board and lower curved portion (turn under) of coach due to less stiffness of coir brush.
• Hence these portions were used to be cleaned manually by available staff.

Developing of Automatic Coach Washing Plant with the keeping in the view of:

1. Less & economical maintenance of the modified washing plant.
2. Less manpower requirement for operation and maintenance this plant.
3. 95% exterior cleaning of a entire rake of 24 coaches is to be achieved
within 35-40 minutes.
4. Reduction in water and soap solution consumption compared to the
conventional Manual coach cleaning.
5. Reduction in power consumption by using automation.
6. Cleaning and disinfection of underneath portion of toilet by High
pressure jets.
7. Bogie side cleaning by high pressure jets.
8. Roof cleaning of Coach by horizontal nylon brush.


Location of ACWP:

Automatic Coach Washing Plants are installed at Starting of Pit Lines in Coaching Depots or Yard.

Process Of Coach Cleaning & Washing in Different
stages:

STAGE-1: Pre-Wash:
▪︎ A rake is moving at speed of 5 KMPH during cleaning & washing of coaches through this plant.
▪︎ In this stage a diffuser type sensor is provided for sensing coaches of a rake.
▪︎ As soon as this sensor senses first coach of a rake, water starts spraying on external surface of coach through number of holes provided on water pipelines erected around in a row.
▪︎ Two sides & roof of coaches are completely wetted by low velocity sprinklers at this stage, some loose dust & dirt is washed away from coach surface and simultaneously, coach surface is made uniformly wet, which help in even application of soap
solution on coach body.

STAGE-2: Spraying of Soap Solution:
▪︎ In this stage, diluted soap solution is sprayed on coach surfaces including two sides and roof through
seven sprinklers.
▪︎ Provision is made for mixing of compressed air with
pressurized soap solution inside the sprinklers to get more bubbles formed
when it strikes with coach surface.
▪︎ Due to release of surface tension in
bubbles, dirt particles are loosened
and washed away easily.
▪︎ Flow &
quantity of soap solution can be
controlled and adjusted by operating
spindle nut on sprinkler and both
valves provided on soap solution
line and pneumatic line.

STAGE-3: Rubbing of Soap Solution:
▪︎ This stage is especially incorporated to get more effective cleaning.
▪︎ In this stage, soap solution is rubbed and made even
application on both sides of coach by two vertical nylon brushes one at each side of coach.
▪︎ This stage comes into action as soon as sensor at second stage is activated.

STAGE-4: Soaking of Soap Solution:
▪︎ In this stage, soap solution is allowed to soak completely for approx.1 minute in normal washing process.
▪︎ This stage is automatically achieved while rake is moving at 5 Km/h. through coach washing plant, since stage 3 and stage 5 is kept apart at 30 meter distance.
▪︎ During this stage, soap solution, is chemically reacted with dirt.

STAGE-5: Cleaning of Underneath Portion of Toilet:
▪︎ In this stage, two sensors are provided for ascertaining the location of underneath toilet portion between two adjacent coaches by sensing of last wheel of first coach and first wheel of second
coach.
▪︎ As soon as these sensors are activated in above situation, pressurized water mixed with disinfectant and phenol, sprayed frombottom through four nozzles which are provided between two rails.
▪︎ This pressurized spray clean underneath portion of toilet and near by area which is normally spoiled with wet soil.
▪︎ This process is also helping in prevention of breeding of cockroaches which generally take place in this area.
▪︎ Further, it also helps in maintaining hygienic conditions for working staff, who specially work or attend safety fittings in this portion of a coach.
▪︎ In this stage, sides of bogie are also cleaned by high pressure water jets simultaneously.

STAGE-6: Moistening of Soap Solution:
▪︎ In this stage, moistening of
partially dried soap solution is carried out by sprinkling of very low-
pressure water through number of nozzles provided on a water pipe line.
▪︎ Hence soap solution applied on roof and sides of coach become wet before
rubbing by horizontal and vertical brushes.

STAGE-7: Coach Cleaning by Horizontal & Vertical Brushes:
▪︎ When coach is moving through this stage, first rubbing of soap solution takesplace at roof portion by horizontal nylon brush mounted on top of the IVth
structure.
▪︎ After this stage, Coach is moving further through 4 sets of vertical cotton brush units (2 Nos on each
side).
▪︎ These brushes are moving at the speed of 150 rpm.
▪︎ Due to centrifugal force, end of each thread of
cotton brushes start rubbing soap solution on coach surface with smooth impact effect thereby whatever
remaining soot and dirt available on surfaces are taken away completely.
▪︎ Cotton thread has good capillary property thus it hold soap solution continuously for longer time.
▪︎ These cotton treads have good flexibility and get required length automatically according to shape of surface of coach so that only tip of threads get touched with coach surface.
▪︎ Cleaning by this method has shown significant effect.
▪︎ These cotton threads are specially given stiffness by fastening with nylon bristles to prevent mingling of cotton threads.
▪︎ Therefore, tips of brushes are reaching, touching and doing cleaning at intricate places on coach body like
window, window sill, window shutter, doors , space near door including door handle, space near to destination board, turn under and roof portion.
▪︎ Earlier, these area could not be possible to clean by old coach washing plant.
▪︎ These brushes are also helping in removing of
reservation chart pasted on a coach.

STAGE-8: After Wash:
▪︎ In this stage, washing of roof and sides of coaches are carried out after rubbing of soap solution by vertical and horizontal brushes.
▪︎ High-pressure water is sprayed on coach surface through eight high-pressure sprinklers to wash coach
completely.
▪︎ In this stage, washing of roof takes place just before
washing of sides by spraying of water through high velocity sprinklers provided at top of structure.
▪︎ This arrangement is made purposely to allow dirty
water after roof washing to flow down on both sides of coaches before washing of sides of coaches.


STAGE-9: Mopping of Water:
▪︎ After wash, coach body become completely wet hence it require mopping.
▪︎ Two vertical brushes with soft cotton threads are provided each on either side.
▪︎ These brushes start mopping of water particles on sides of coaches as soon as coaches pass through these brushes.
▪︎ This stage is specially effective for cleaning of AC glass windows where small water drops are always sticking and staining glass giving discomfort to passengers when they are looking outside through such windows.
▪︎ These brushes are also used for buffing of coaches to get shining by rotating it in dried condition when rake is moved from pit-line after examination.
▪︎ Since, requirement of soap solution is less for
external cleaning of rake by this washing plant.
▪︎ Cost incurred in normal external cleaning of a rake of 21 coaches is Rs.400 approximately. This cost includes cost of material like soap solution and
cotton ropes (which are normally replaced once in a month) and cost of electrical power.

The cost for installation of Automatic Coach Washing Plant is 4 cr.




Source: Some information gather from RDSO.

Pic Source: Khagaria Jn. & Google
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