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NORTH WESTERN RAILWAY, JAIPUR
BY
AWANISH KUMAR
13EJAME014
-: CONTENT :-
1. Introduction
2. Organisation Structure
3. North Western Railway
4. Wheels
5. Machine Shop
6. Breaking System
7. Bogie Shop
8. Spring Shop
-: INDIAN RAILWAY :-
First passenger train introduced in India on 16 April 1853 between Mumbai to
Thane (34 km).
Over 10,000 trains daily, transporting over 8,900 million passengers and over
1050 million tones of freight per year.
Indian Railways is the world's ninth largest organisation, by number of
employees, with over 1.4 million employees.
As of 31 March 2013, 23,541 km (36%) of the total 65,000 km route length was
electrified.
The number of zones in Indian Railways increased from six to eight in 1951,
nine in 1952 and sixteen in 2003. Presently there are 17 zones & 84 divisions.
INTRODUCTION
Name Abbr. Headquarters
Central Railway CR Mumbai
Eastern Railway ER Kolkata
East Central Railway ECR Hajipur
East Coast Railway ECoR Bhubaneswar
Konkan Railway KR Panvel
Northern Railway NR Delhi
North Central Railway NCR Allahabad
North Western Railway NWR Jaipur
North Eastern Railway NER Gorakhpur
Northeast Frontier Railway NFR Maligaon(Guwahati)
Southern Railway SR Chennai
South Central Railway SCR Secunderabad
South Eastern Railway SER Kolkata
South East Central Railway SECR Bilaspur, CG
South Western Railway SWR Hubli
Western Railway WR Mumbai
West Central Railway WCR Jabalpur
Kolkata Metro KMR Kolkata
ZONES OF INDIAN RAILWAY
Department Of Indian Railway
Sr.
No.
Name of Department Role And
Function
1. Engineering Department
Maintenance of all
Fixed Assets
2. Mechanical Engineering & power
Department
Maintenance of all
Rolling Stock of the
division
3. Electrical Engineering Department Maintenance of all
electric locomotives
4. Signal & Telecommunication Engg.
Department
Maintenance of the
Signaling &
Telecommunication
5. Operation and Traffic Department Train operations
6. Commercial Department Passenger Ticketing,
Ticket checking,
booking of freight
rakes, collecting fare
Department Of Indian Railway
S.No
.
Name of Department Role And Function
7. Medical Department Providing Medical
Facility to Railway
employee & their
Family too.
8. Safety Department Ensuring safety of
Train operations
9. Store Department Ensuring material
for maintenance of
Trains
10. Account Department Financial
management of the
division
11. Security Department Security of Railway
material, passenger
and passenger
belonging
 Reporting mark : N.W.R
 Founded : 1st Oct. 2002
 Headquarters : Jaipur, Rajasthan
 General Manager : Anil Singhal
 Track Gauge : 1,676mm (5 ft. 6in)- Broad
Gauge
:1000mm(3ft.3 3/8in) – Meter Gauge
 Length : 6559.546
 Station : 578
 Division : 4
 Website :
http://www.nwr.indianrailways.gov.in/
Map Of North Western Railway
IN THIS SHOP, REPAIR WORK OF THE WHEEL AND AXEL IS UNDER
TAKEN. AS IT IS KNOWN THAT, THE WHEEL WEARS THROUGHOUT
ITS LIFE.
WHEEL
Typ
e
Wheel
dia.(mm) Distance b/w journal
center (mm)
Journal
size(mm)
Axel wheel
seat dia. (mm)
ICF 915 2159 120*113.5 172,0.25,0.35
BME
L
915 2210.2 120*179 171,0.45,0.63
The diameter of new wheel is-
( Table 3.1 list of wheels dimension )
Wheel testing & machining
Axial journal testing lathe
In this shop wheel sets are removed from the bogies, the
entire wheel is first inspected for assessing the condition of the
component of wheel such as axel trial wheel disc and
guttering.
The shop consist of-
1. Axel journal testing lathe.
2. Hydraulic wheel press with facility of mounting.
3. Vertical turning lathe.
Hydraulic wheel presses with a facility
of mounting
Vertical turning lathe
External and internal diameter is corrected by this lathe; wheel
is tightened on the rotating clutch. The stationary is carbide tool
cut the wheel to correct diameter.
-: THE MAINTENANCE SCHEDULES AND THE OVERHAULING PERIODS :-
1. Trip schedule- After every trip by primary
maintenance depot.
2. Schedule A - Monthly (1 month )
3. Schedule B - Quarterly (3 months )
4. IOH – 9 months
5. POH – 18 months
Periodic overhauling is the best available process of maintenance of coaches in India. This
generally operated after 18 months after the manufacturing or the previous periodic
overhauling done in any workshop. This undergoes a huge process of lifting the coach,
isolating the all parts, and changing or replacing the necessary or damaged parts. In other
words this is the process of renewing the coaches.
> POH <
-It stands for periodic overhauling.
-POH is allowed in nominated workshops only.
-Painting of whole coach is necessary.
-Profiling of wheel is necessary
-: WHEEL
PROFILE :-
-: DEFECTS :-
Thin Flange :- When the flange thickness reduces from 28.5 mm to 16
mm or less, then the flange is called thin flange.
Sharp Flange :- When the radius given at the tip of flange is worn out from
14.5mm to 5 mm or less is called Sharp Flange.
Thin Tyre :- If the remaining thickness of tyre is less than 25 mm, it is called
thin tyre.
Hollow Tyre :- If the groove on the wheel tread is up to 5 mm or more, it is
called Hollow tyre.
MACHINE SHOP
Machines are two types…
1. AUTOMATIC.
2. MANUALLY.
There are three types of automatic machine.
• Numerical control.
• Computer numerical control.
• Direct numerical control machine.
Automatic Control
Computer Numerical Control
Manually Operated Machine
Drilling operation is carried out here. A
large for the operation .To complete the
operation faster a few gauge milling
machine are also provides.
All the lathes have four jaws chuck for
better holding centering is done either
manually or with the help of universal
scriber. All kinds of turning are performed
here.
Drilling Section Centre Lathe Section
Manually Operated Machine
The machine is also called horizontal
shaping machine. It works on quick-return
mechanism .The arm of shaper
reciprocating horizontal. The cutting takes
place only in the forward stroke.
The is vertical shaping machine
.The arm reciprocating in the
vertical direction. Most parts are
the same as shaper .
Shaper Slotter
BREAKING SYSTEM
BRAKING SYSTEM
In Air Brake system compressed air is used for operating the brake system. The
locomotive compressor charges the feed pipe and the brake pipes throughout the
length of the train. The feed pipe is connected to the auxiliary reservoirs and the
brake pipe is connected to the brake cylinders through the distributor valve. Brake
application takes place by dropping the pressure in the brake pipe.
-: AXLE :-
It is the main long cylindrical bar on which bogie are fixed with the help of bearings. This
is made of steel as above. Each axle contains 2 wheels, the brake cylinders are also
attached to it and in case of LHB coaches, the braking discs are fixed on to the axle.
The axle mounted brake disc consists of a gray cast iron friction
ring and a cast steel hub, connected by means of radially
arranged elastic resilient sleeves which are secured in the hub by
means of hexagon screws. The friction ring is manufactured as a
solid component or in a split version. In the latter case, the two
halves are held together by two tight –fit screws.
DISC
-: AIR BRAKE SYSTEM
:- The brake system in which compressed air is used in the brake
cylinder for the application of brakes is called air brake system.
MAIN COMPONENTS :-
Control Reservoir 9 liter, 5 kg/cm2 Auxiliary Reservoir
200 liter, 6 kg/cm2
Brake pipe – Dia. 32 mm Feed Pipe – Dia. 25
-: BRAKE SHOE :-
The brake shoe is provided with a brake
pad holder carrying replaceable pads.
The brake shoe consists of the brake pad
holder, the vertical pins and the brake pad.
SHOESDue to BC pressure, the piston moves
forward and strikes against the brake caliper.
The lever arm of the brake caliper presses
onto the disc brake through the brake shoe.
The disc brakes are mounted on the wheel
axle and so rotate along with the wheels.
Due to application of brake shoes, the discs
begin to lose their angular speed.
As a result the axle also begins to slow down
since the two are connected.
Ultimately, the wheels stop rotating as they
are mounted on the same axle.
1.Bogie frame longitudinal component
2. Cross-beam
BOGIE SHOP
The frame is made up of two longitudinal components………
 (1) connected by two cross-beams
(2) which also support the brake units. The various supports which
connect the different bogie components are welded to the frame.
FLOW PROCESS OF A BCNHL WAGON
During welding in a BCNHL wagon various welding techniques are used like flat welding,
horizontal welding, vertical welding,overhead welding, etc. But it is always preferred to weld as flat
welding. So wherever possible, by using manipulators,work piece is so adjusted that it can be
welded as flat or horizontal. It increases the efficiency of worker and it is also safe to do.
(Fig 6.7 fixed manipulator)
-: WINDOW UNITS :-
 The sealed window units consist of 8.4 mm outer glass
and 4 mm inner glass with 6 mm Argon gas filled.
 Argon is an inexpensive, non-toxic,
odorless gas .
 It increase sound proofing
characteristics of the
window.
 Minimizes heat exchange through the
window.
 Argon will not corrode the window
material.
 This type of windows can even block
ultraviolet
rays.
SPRING SHOP
• In this section the helical is prepared. For this purpose there certain machine for
testing, grading and repairing it.
Visual and magnetic crack detection
CAUSE PERCENTAGE OF FAILURE
Free of height 8.93%
Load test 82.08%
Dent mark, corrosion & breakage 08.39%
Thanks For your Support

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North Western Indian Railway,Jaipur, Rajasthan 2016

  • 1. NORTH WESTERN RAILWAY, JAIPUR BY AWANISH KUMAR 13EJAME014
  • 2. -: CONTENT :- 1. Introduction 2. Organisation Structure 3. North Western Railway 4. Wheels 5. Machine Shop 6. Breaking System 7. Bogie Shop 8. Spring Shop
  • 3. -: INDIAN RAILWAY :- First passenger train introduced in India on 16 April 1853 between Mumbai to Thane (34 km). Over 10,000 trains daily, transporting over 8,900 million passengers and over 1050 million tones of freight per year. Indian Railways is the world's ninth largest organisation, by number of employees, with over 1.4 million employees. As of 31 March 2013, 23,541 km (36%) of the total 65,000 km route length was electrified. The number of zones in Indian Railways increased from six to eight in 1951, nine in 1952 and sixteen in 2003. Presently there are 17 zones & 84 divisions. INTRODUCTION
  • 4. Name Abbr. Headquarters Central Railway CR Mumbai Eastern Railway ER Kolkata East Central Railway ECR Hajipur East Coast Railway ECoR Bhubaneswar Konkan Railway KR Panvel Northern Railway NR Delhi North Central Railway NCR Allahabad North Western Railway NWR Jaipur North Eastern Railway NER Gorakhpur Northeast Frontier Railway NFR Maligaon(Guwahati) Southern Railway SR Chennai South Central Railway SCR Secunderabad South Eastern Railway SER Kolkata South East Central Railway SECR Bilaspur, CG South Western Railway SWR Hubli Western Railway WR Mumbai West Central Railway WCR Jabalpur Kolkata Metro KMR Kolkata ZONES OF INDIAN RAILWAY
  • 5. Department Of Indian Railway Sr. No. Name of Department Role And Function 1. Engineering Department Maintenance of all Fixed Assets 2. Mechanical Engineering & power Department Maintenance of all Rolling Stock of the division 3. Electrical Engineering Department Maintenance of all electric locomotives 4. Signal & Telecommunication Engg. Department Maintenance of the Signaling & Telecommunication 5. Operation and Traffic Department Train operations 6. Commercial Department Passenger Ticketing, Ticket checking, booking of freight rakes, collecting fare
  • 6. Department Of Indian Railway S.No . Name of Department Role And Function 7. Medical Department Providing Medical Facility to Railway employee & their Family too. 8. Safety Department Ensuring safety of Train operations 9. Store Department Ensuring material for maintenance of Trains 10. Account Department Financial management of the division 11. Security Department Security of Railway material, passenger and passenger belonging
  • 7.  Reporting mark : N.W.R  Founded : 1st Oct. 2002  Headquarters : Jaipur, Rajasthan  General Manager : Anil Singhal  Track Gauge : 1,676mm (5 ft. 6in)- Broad Gauge :1000mm(3ft.3 3/8in) – Meter Gauge  Length : 6559.546  Station : 578  Division : 4  Website : http://www.nwr.indianrailways.gov.in/
  • 8. Map Of North Western Railway
  • 9. IN THIS SHOP, REPAIR WORK OF THE WHEEL AND AXEL IS UNDER TAKEN. AS IT IS KNOWN THAT, THE WHEEL WEARS THROUGHOUT ITS LIFE. WHEEL Typ e Wheel dia.(mm) Distance b/w journal center (mm) Journal size(mm) Axel wheel seat dia. (mm) ICF 915 2159 120*113.5 172,0.25,0.35 BME L 915 2210.2 120*179 171,0.45,0.63 The diameter of new wheel is- ( Table 3.1 list of wheels dimension )
  • 10. Wheel testing & machining Axial journal testing lathe In this shop wheel sets are removed from the bogies, the entire wheel is first inspected for assessing the condition of the component of wheel such as axel trial wheel disc and guttering. The shop consist of- 1. Axel journal testing lathe. 2. Hydraulic wheel press with facility of mounting. 3. Vertical turning lathe. Hydraulic wheel presses with a facility of mounting
  • 11. Vertical turning lathe External and internal diameter is corrected by this lathe; wheel is tightened on the rotating clutch. The stationary is carbide tool cut the wheel to correct diameter.
  • 12. -: THE MAINTENANCE SCHEDULES AND THE OVERHAULING PERIODS :- 1. Trip schedule- After every trip by primary maintenance depot. 2. Schedule A - Monthly (1 month ) 3. Schedule B - Quarterly (3 months ) 4. IOH – 9 months 5. POH – 18 months Periodic overhauling is the best available process of maintenance of coaches in India. This generally operated after 18 months after the manufacturing or the previous periodic overhauling done in any workshop. This undergoes a huge process of lifting the coach, isolating the all parts, and changing or replacing the necessary or damaged parts. In other words this is the process of renewing the coaches. > POH < -It stands for periodic overhauling. -POH is allowed in nominated workshops only. -Painting of whole coach is necessary. -Profiling of wheel is necessary
  • 13. -: WHEEL PROFILE :- -: DEFECTS :- Thin Flange :- When the flange thickness reduces from 28.5 mm to 16 mm or less, then the flange is called thin flange. Sharp Flange :- When the radius given at the tip of flange is worn out from 14.5mm to 5 mm or less is called Sharp Flange. Thin Tyre :- If the remaining thickness of tyre is less than 25 mm, it is called thin tyre. Hollow Tyre :- If the groove on the wheel tread is up to 5 mm or more, it is called Hollow tyre.
  • 14. MACHINE SHOP Machines are two types… 1. AUTOMATIC. 2. MANUALLY. There are three types of automatic machine. • Numerical control. • Computer numerical control. • Direct numerical control machine.
  • 16. Manually Operated Machine Drilling operation is carried out here. A large for the operation .To complete the operation faster a few gauge milling machine are also provides. All the lathes have four jaws chuck for better holding centering is done either manually or with the help of universal scriber. All kinds of turning are performed here. Drilling Section Centre Lathe Section
  • 17. Manually Operated Machine The machine is also called horizontal shaping machine. It works on quick-return mechanism .The arm of shaper reciprocating horizontal. The cutting takes place only in the forward stroke. The is vertical shaping machine .The arm reciprocating in the vertical direction. Most parts are the same as shaper . Shaper Slotter
  • 18. BREAKING SYSTEM BRAKING SYSTEM In Air Brake system compressed air is used for operating the brake system. The locomotive compressor charges the feed pipe and the brake pipes throughout the length of the train. The feed pipe is connected to the auxiliary reservoirs and the brake pipe is connected to the brake cylinders through the distributor valve. Brake application takes place by dropping the pressure in the brake pipe.
  • 19. -: AXLE :- It is the main long cylindrical bar on which bogie are fixed with the help of bearings. This is made of steel as above. Each axle contains 2 wheels, the brake cylinders are also attached to it and in case of LHB coaches, the braking discs are fixed on to the axle. The axle mounted brake disc consists of a gray cast iron friction ring and a cast steel hub, connected by means of radially arranged elastic resilient sleeves which are secured in the hub by means of hexagon screws. The friction ring is manufactured as a solid component or in a split version. In the latter case, the two halves are held together by two tight –fit screws. DISC
  • 20. -: AIR BRAKE SYSTEM :- The brake system in which compressed air is used in the brake cylinder for the application of brakes is called air brake system. MAIN COMPONENTS :- Control Reservoir 9 liter, 5 kg/cm2 Auxiliary Reservoir 200 liter, 6 kg/cm2 Brake pipe – Dia. 32 mm Feed Pipe – Dia. 25
  • 21. -: BRAKE SHOE :- The brake shoe is provided with a brake pad holder carrying replaceable pads. The brake shoe consists of the brake pad holder, the vertical pins and the brake pad. SHOESDue to BC pressure, the piston moves forward and strikes against the brake caliper. The lever arm of the brake caliper presses onto the disc brake through the brake shoe. The disc brakes are mounted on the wheel axle and so rotate along with the wheels. Due to application of brake shoes, the discs begin to lose their angular speed. As a result the axle also begins to slow down since the two are connected. Ultimately, the wheels stop rotating as they are mounted on the same axle.
  • 22. 1.Bogie frame longitudinal component 2. Cross-beam BOGIE SHOP The frame is made up of two longitudinal components………  (1) connected by two cross-beams (2) which also support the brake units. The various supports which connect the different bogie components are welded to the frame.
  • 23. FLOW PROCESS OF A BCNHL WAGON
  • 24. During welding in a BCNHL wagon various welding techniques are used like flat welding, horizontal welding, vertical welding,overhead welding, etc. But it is always preferred to weld as flat welding. So wherever possible, by using manipulators,work piece is so adjusted that it can be welded as flat or horizontal. It increases the efficiency of worker and it is also safe to do. (Fig 6.7 fixed manipulator)
  • 25. -: WINDOW UNITS :-  The sealed window units consist of 8.4 mm outer glass and 4 mm inner glass with 6 mm Argon gas filled.  Argon is an inexpensive, non-toxic, odorless gas .  It increase sound proofing characteristics of the window.  Minimizes heat exchange through the window.  Argon will not corrode the window material.  This type of windows can even block ultraviolet rays.
  • 26. SPRING SHOP • In this section the helical is prepared. For this purpose there certain machine for testing, grading and repairing it. Visual and magnetic crack detection CAUSE PERCENTAGE OF FAILURE Free of height 8.93% Load test 82.08% Dent mark, corrosion & breakage 08.39%
  • 27. Thanks For your Support