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Carriage Repair Shop, Tirupathi is located beside RENIGUNTA - TIRUPATHI Mainline. Due P.O.H. coaches are taken into workshop from RENIGUNTA station and are placed in marshaling line for reversing the Locomotive. Coaches are then separated type wise namely AC, Non-AC, LHB & condemnation coaches and sent to incoming shop. The following works are carried out in incoming shop: Coach cleaning, stripping of electrical items like lights, fans, WRA motors, RBCR/EBCR & Batteries, Stripping of Berths, unloading of RMPU, testing of RMPU trough for corrosion & leakage, testing of WSP system for defects & testing of Pressurized Flushing system, stripping of under gear connections like hoses, center pivot cotters, Safety Brackets and Shock absorbers/Dampers. After completion of all stripping activities, all stripped components are sent to concerned sections for overhauling & testing. Coach is then moved to CF - Lift & Lower shop for lifting and placement on stands through EOT crane. After lifting ICF Bogies are sent to de-wheeling section & LHB Bogies are sent to LHB Bogies section for bogie stripping. The following activities are carried out after lifting the coach - Unloading of Bio-Tanks, cleaning of under-frame like solebar, head stock, cross bars, pipeline, Inspection of under frame, Side & end panels for any corrosion and damages. If any coach is marked as HR, the same is lowered on Dummy Bogies and sent to corrosion shop for corrosion attention. If coach is marked as normal corrosion, under gear works will be carried out. Under gear attention consists of Initial testing of airbrake system, attention of pipeline, replacement of all airbrake components with overhauled components, attention of Center pivot and side barrier, attention of CBC couplers, screw couplers & Buffers etc. Components that are removed from coach namely valves, cocks, DV etc., are sent to airbrake component shop. After attention of under gear components, coaches are lowered on POHed Bogies and are sent to furnishing shop for further attention. Simultaneous to lift & lower activity, work on unit exchange spares is carried out i.e. Overhauling of Bogies, Overhauling of Air Brake components and Overhauling of Wheel sets & springs. Stripping of ICF Bogies is carried out in De-wheeling section by using EOT crane. Stripped components are sent to respective shops i.e. Wheel sets to wheel shop for attention, Bogie and its components to shot blasting area for cleaning and further to painting area for painting with one coat of red oxide and one coat of black enamel. After drying of paint, the bogies are assembled in Bogie assembly section. After completion of assembly, Bogie frames are re-wheeled with POHed wheels. POHed bogies are sent to CF- Lift and Lower shop for lowering the coach. Stripping of LHB FIAT Bogies is carried out in LHB FIAT bogie section by using EOT crane, Secondary pressing equipment & Bogie manipulator. After dismantling, Wheel sets are sent to wheel shop and other components are sent to shot blasting for cleaning. Cleaned bogies are painted with PU primer and finish coat and is let to dry. After drying, assembly of Bogie is carried out and bogies are sent to Lift & Lower shop for lowering the coach. In CF shop attention of MEMU motor coaches is also carried out namely: unloading, overhauling, testing and loading of Traction Motors, overhauling and re-fitting of air brake components like compressors, Coolers, brake cylinders, Transformers & relay etc. In wheel shop, ICF Wheel sets, old wheel sets are received at stripping section where axle boxes are stripped, bearing are extracted and both are cleaned. Wheel sets are then sent to machine shop for measurements and turning and burnishing. Re-disking is done if required. After machining works, wheels sets are sent to assembly area for assembly. In assembly section bearings are tested, loaded on axle and greased. Subsequently, axle box assembly works are carried out. After completion of wheel sets, assembly number plates are provided and wheel sets are sent to Bogie shop. LHB wheel sets are received at LHB wheel section and Discs, axle and brake disc & CTRB are cleaned. Ring oiler, phonic wheel & end caps are stripped and bearing is extracted and mounted if its life is less or condition is not good. Re-disking of brake disc is done if required. Following tests are carried out namely de-magnetization, end play testing etc. After completion of assembly, bogies are sent to FIAT bogie section for utilization. In Corrosion shop, corrosion repairs are carried out namely Sole bar attention, lavatory portion attention, Head stock attention, Turn under, side body, end body and trough floor and roof attention. After completion of corrosion attention, coaches are sent to CBR shop for attention of furnishing items. In CBR shop, all furnishing items are attended namely Wooden floor, PVC flooring, carpentry works, passenger amenities, passenger safety items, Vestibule rubbers, Follower plates, Banjo shutter, Glass shutters, window glass, Sealing patches, Side & portion wall panels, chequered sheets in doorways, Battery box dropping & Fitting, Main doors, lavatory doors, end wall sliding doors, seat legs, Rolling shutters, under slung & overhead water tanks, water line pipeline attention, filling of water and electrical panel doors etc. After completion of all furnishing items, coaches are sent to paint shop for painting and HR marked coaches are sent to CF for under gear attention and lowering on POHed bogies which are then sent to Paint shop for Painting. In Paint shop, two layers of putty is applied on coach body during the first day. Simultaneously interior painting namely Roof sealing, seat pillars, seat numbers, caution stickers etc is carried out. During second day two coats of exterior painting is applied and lettering is done. The following works are also carried out: fitment of seats & berths, fitment of lights and Fans. After completion of Painting works, coaches are sent to outgoing shop. Simultaneously to the work carried out on coach body from Incoming shop to Paint shop, the following unit exchange spares are overhauled namely overhauling of lights & fans, Repair & Trimming of Seats & Berths, overhauling of electrical components i.e. Alternators, transformers, Tension gears etc., overhauling of RMPU units, Testing of batteries, overhauling of WRA equipment etc. In outgoing shop, Batteries & RMPUs are loaded and bio-tanks are fitted to the coach. After completion of these fittings, coaches are placed for alteration for obtaining buffer height by providing CR rings in suspension system. After completion of alteration, under gear connections are given namely hose pipe connections, center pivot cotters, electrical connections and final testing of air brake & Electrical etc. For AC coaches, after completion of these works, coaches are placed on dyno drive pit line for testing of dyno drive to adjust the regulator. After completion of these works, coaches are offered for NTXR examination. After getting fit from NTXR, coaches are cleaned thoroughly by using different chemicals and offered to IOR for inspection of POH quality. After inspection of IOR, coaches are sent to divisions for Traffic use. In addition to these POH activities, this workshop has good water management system in the form of ETP plants of 80KLD combined capacity, rainwater harvesting pond of capacity 28500 KL and one STP plant. ETP consists of 30 KLD and 50 KLD plants. By using these plants this workshop is using processed water for cleaning the coaches and watering plants. Rainwater harvesting pond is available at north east corner of workshop. It is used to collect rain water during rainy season for utilizing the same during summer season. The STP plant (constructed wet lands) is available at Administrative block for treating the waste water from CRS colonies. Treated water is utilized for plants in the Administrative block. This workshop also has drip irrigation system for better utilization of water. 590kWp capacity of solar panels installed at various locations cater to approximately 50% of workshop load.