vocational training in secr bilaspur engneering 4th semester

1. VOCATIONAL TRAINING REPORT
ON
SECR RAILWAY BILASPUR
Session 2017-18
RUNGTA COLLEGE OF ENGNEERING &
TECHNOLOGY
Submitted by
PRASHANT KUMAR PATEL
(Mechanical)
Guided By–
Shri Pravin kumar (SSE/CHG/BSP)
Gunjan wasnik (Sr. CDO/BSP)

2. ACKNOWLEDGEMENT
This project work is based on my B.E. 4th
semester vocational
training at SECR, Bilaspur. A large number of people had given
me valuable knowledge which I have incorporated in this work.
It is not possible for me to acknowledge all of them individually.
I take this opportunity to express my gratitude to them. However
Shri Pravin kumar (SSE/CHG/BSP) had granted me a great
opportunity to complete my vocational training at SECR,
Bilaspur, I am very much thankful to him. I am also beholden to
Gunjan wasnik (Sr. CDO/BSP) & all the SSE’s of various
railway yards at Bilaspur. And I am also thankful to all the
supervisors & workers of various yards for their support &
knowledge.
I wish to acknowledge my sincere thanks to my college RCET,
BHILAI for granting me this opportunity.
Name –PRASHANT KUMAR PATEL
Branch – Mechanical

3. CONTENT
S.No. TOPIC DATE
1 Major sick line
(MSL)
15/06/2017 -
23/06/2017
2 BCN Depot 24/06/2017 –
04/07/2017
3 Coaching Depot 05/07/2017 –
14/07/2017

4. INTRODUCTION
Indian Railways (reporting markIR) is an iconic Indian organisation,
owned and operated by the Government of India through the Ministry of
Railways. Indian Railways has 114,500 kilometres (71,147 mi). of total
track over a route of 65,000 kilometres (40,389 mi) and 7,500 stations. It
has the world's fourth largest railway network after those of the United
States, Russia and China. The railways carry over 30 million passengers
and 2.8 million tons of freight daily. In 2011-2012 Railway earnt
104,278.79 crore (US$20.8 billion) which consists of 69,675.97 crore
(US$13.9 billion) from freight and 28,645.52 crore (US$5.71 billion)
from passengers tickets.
Indian Railways is the world's fourth largest commercial or utility
employer, by number of employees, with over 1.4 millionemployees.|~|

5. MAJOR SICK LINE
o INTRODUCTION
Sick line is a place where repairing of wagons has been done
during running period. There are 6 no. of lines in the yard. Line
no. 1 is outgoing yard i.e. empty rakes which are repaired left
for the different loading points. Line no.2 to 4 are used for sick
collection line, sick line, engine line .And line no.6 is used for
incoming yard, i.e. unloaded rakes from different loading and
unloading point come to sick line. These rakes are

6. thenintensively examined by c&w staff as per schedule. Time
taken 3hrs to 31/2hrs.
After giving fit, sick wagons are being dispatched to the
operating department. Then the rakes are finally ready for
departure to loading points.
WORKS UNDERTAKEN ATMSL
1. DOOR REPAIRING
2. WHEEL CHANGING
3. CBC REPAIRING
4. BRAKE SHOE REPLACING
5. WELDING/CUTTING
6. SCRAPPING
7. BRAKE SYSTEM CHANGING
TYPES OF WAGON REPAIRED IN MSL
1. BOXNHS
2. BOBRN
3. BOBY
4. BCN
5. BRHNEHS
6. BOXNM
7. BOXNHL

7. BCN DEPOT
o INTRODUCTION
The over hauling (both POH and ROH) of wagons are done at
BCN
Is carried out the bogie section and the body section. The
body is lifted and trolleys are run out and the body is kept on
tussle. Bogies are sent to bogie section.

8. o MACHINES AND EQUIPMENTS IN BCN DEPORT
 Welding plant
 EOT crane-2nos. capacity 15 ton
 EOT crane-2nos. capacity 5 ton
 Surface wheel lathe
 Shearing machine
 Black smith shop
 Painter shop
 Model room for trainees
 Material handling equipment’s
 CTRB bearing installer
 2 CNC lathe machine

9. WHEEL SPECIFICATIONS
1. NEW AND CONDEMNING SIZE OF WHEELS
(ALL THE DATA IS IN MM.)
WHEEL
TYPE
NEW
CONDEM
NING
MIN.SHOP
ISSUE SIZE
IRS
SOLID 1000 990 996
TYRED 1000 1015 1021
BOXN-
BCN
SOLID 1000 925 931
TYRED - - -
BOX-CRT
SOLID 1000 860 866
TYRED 1000 902 908
ICF
SOLID 915 813 819
TYRED 915 851 857
BEML
SOLID 914.5 813 819
TYRED 914.5 838 844

10. Wheels and Wheel Defect
 THIN FLANGE-16 MM.(28.5MM)
 SHARP FLANGE-5 MM.(14MM)
 DEEP FLANGE-35 MM.(28.5MM)
 THIN TYRE-LESS THAN NORMAL
 FLAT SURFACE ON TYRE
 HOLLOW TYRE-5 MM.HOLE ON
SURFACE
 ROUTE RADIUS LOW-13 MM(16 MM)

11. ROH EXAMINATION
o INTRODUCTION
Routine over hauling is done after 18 months for general
rakes and after 12 months for c.c. rakes.
o BRIEF WORKING PROCEDURE OF WAGONS
1) Lift body and keep it on test
2) Run out bogie.
3) Attention of bogie.
4) Clean the bogie and ensure no cracks on bogie parts.
5) Attention of brake gear, strip up visual examination of
all components replace of worn out/damage parts.
6) Rehabilitation procedure for bogies to be attended I all
indicated location.
7) Matching of spring.
8) Examination of pivots, side bearers.
9) Wheel base trammeling of bogies.
10) Modification bogie to be under taken as
recommendation by RDSO and local instruction. All
pins to be secured with U brackets (suspension pins).
11) Four wheel sets with new WWP profile with equal
diameter to replaced, ensure roller bearing are all in
good condition by rotating.

12. 12) Examine to pivot casting and security arrangements
with pivot pins assembly lubricant pivots.
13) Examine body, brake gear.
14) Test SAB/el box.
15) Recommended RDSO/Local modification is attended
on body, brake gear.
16) Examination of CBC components:
 Knuckle with all gauges.
 Draft gear and its parts.
 Yoke follower pin to be ensure.
 Examine CBC coupler casting and knuckle with contour
gauge.
 CBC operating handle/ant creep arrangement.
17) Ensure correct riveting and YSP, PSP to be homed
with contour gauge.
18) Horizontal level to be lubricated with graphite grease.
19) Proper welding procedure to be followed.
20) Body door arrangement and fastening to be examined
and lubrication to door hinges to be ensure.

13. 21) Air brake:
 Leakage test on wagon.
 Drain out AR and CR.
 Ensure pipe holding clamps intact.
 Over haul brake cylinder.
 Over haul angle cock.
 DV to be tested either by single car or on test bench.
 Recommended RDSO modification to be attended.
 After completion of entire jobs single car testing of
wagons to be attended.
 Test SAB, empty load device, piston stroke.
22) Stencil station code date on sole bar corners brake cylinder,
AR, CR, bogies and wheels etc.
23) Paint corroded locations such as door wagons sole bar
touch up wagon number/tare/area/return date.

14. POH OF WAGONS
o INTRODUCTION
After a certain period of running during service the wagons
are sending to the workshop for their periodical over hauling
(POH). The period of running between two successive POH is
different for the wagons, due to factors depending on type of
wagon, its uses, the material and chemical action which it
carried, the bulkiness of the material, the construction
features.|
Railway workshop undertakes the POH of wagon such
overhaul consists of lifting, through examination of all parts
of a wagon and its gear and the execution of such repair may
be necessary to enable the wagons to run for the full period
until the next POH.
o BRIFE WORKING PROCEDURE OF POH
The POH of wagon consists of two sections, body and bogie
section. The body is lifted and trolleys are run out the body is
kept on tussle. Bogies are sending to bogie section.

15. 1) Vacuum cylinder stripped and sends to vacuum
cylinder repair shop.
2) Brake gear, draw gear, buffing gear is stripped,
examine and repair.
3) Under frame members, center pivot, side bearer are
built up welding or changed.
4) Brake gear are units, pins are checked and replace if
required.
5) The alignment of bogie is checked and corrected.
6) Bearing spring, suspension gear are checked and
corrected.
7) After completion of all repairs, the bogie are measure
on to the wheels and return to the body section where
the body is lowered on then necessary to repaired. After
finishing touches painting etc. the wagon is to NTXR
for examination.

16. ART (ACCIDENTAL RELIFE TRAIN)
o INTRODUCTION
Accidental relief train is useful in case of accident and brake
down region. This train is full of required equipment for relief.
The detail of equipment is divided in following categories:-
 Hydraulic equipment
 Hand tool
 Lighting equipment
 Electrical cutting tool
 Safety equipment
 Equipments:-
 Hydraulic jack
 Control stand
 Power pack

17.  Demolition hammer
 Detonator (produce sound)
 Red green flag
 Re railing bridge (rolling)
 Breathing apparatus
 Gas cutters
 Roller carriage with jack
 Pulling device
 Folding tent
 Sealing kit
 Claw jack (850mm rod. Piston)
 Petromax
 Wooden wedge
 Helmets + jackets+ hand gloves
 Gas cylinder
 Telescopic jaw (50T, 25T more than 1 piston)
 Holding rope
 Axle pushes
 Spanner
 Tool box
 Torch
 Gum boot
 Pull and push trolley
 Gas cutter and Drilling machine

18. o ARME (Electrical)
 Diesel generator 3Ø
 Portable diesel generator
 Power light with PG& trunk
 Halogen fitting
 Exhaust fan
 Battery charger
 TFL fitting
 Ladder
 D.O.E spanner set
 Torch
 Water jar

19. COACHING -DEPOT
o INTRODUCTION
The over hauling and maintenance of coaches are doneat
coaching yard.
o The followingactivities are performed at coaching
yard
 Primary maintenanceof 9 trains (22 rakes)
 Secondarymaintenance of 4 trains (11 rakes)
 9 month IOH of coaches – 35 per month.
 Sick repair of 90 coaches per month.

20. WORKPERFORMAT COACHING DEPORT
Break down maintenance of coaching stock between
consecutive overhauls the coaches undergo the schedule
called the intermediate lifting. At coachingsick line the
coaching stock lifted with the plain bearing axle boxes as
distinguish from roller bearing axle boxes undergo the
process of repacking as the following process of
periodicity.
Since the coaches are required to be lifted off the wheels
for repacking, the intermediate lifting in normally planed
to consider the repacking. The repacking consists
examination of all the componentsof the axle box
assembly i.e. bearing brass, splitter plate, journal etc. and
replacement of oil packing with necessary repairs. The
axle boxes fitted with roller bearing are examined in the
workshop during overhauling maintenance.|~|

21. ICF COACH
ICF COACH is a conventional railway COACH used on the
majority of Indian Railway main line passenger coaches. The
design of the bogie was developed by ICF (Integral Coach
Factory), Perumbur, India in collaboration with the Swiss Car &
Elevator Manufacturing Co., Schlieren, Switzerland in the
1950s. The design is also called the Schlieren design based on
the location of the Swiss company.
Parts of bogie:
• Bogie frame
• Bogie bolster
• Center pivot pin
• Wheels
• Roller bearing assembly
• Side bearers

22.  Suspension System:
• Primary suspension
• Secondary suspension
• Lower spring beam
 Braking System
• Brake beam assembly
• Brake head
• Brake blocks
• Brake levers
• Brake cylinder

23. SUSPENSION SYSTEM
ICF bogie consists of two types of suspension systems.
 Primary Suspension
 Secondary Suspension
BUFFER SYSTEM
BRAKING SYSTEM
• ICF bogie uses bogie mounted air brake system.
• In a ICF bogie the brake cylinder is mounted on the bogie
frame itself.
• Braking system consists of
1. Brake cylinder
2. Brake beam
3. Brake head
4. Brake block

24. AIR BRAKE
o INTRODUCTION
Air brake is the brake system used in rolling stock in which
the media of brake application is compressed air. In this
system reservoir braking power in the form of compressed air
is stored in to and out of the brake cylinder is governed by a
control valve/distributor valve actuated by the brake pipe
pressure which runs throughout the length of the train. The
pressure in the brake pipe is controlled by driver’s brakes
valve from the locomotive when a compressor provided a
compress air reservoir.

25. o NECESSITY OF AIR BRAKE
Vacuum brake system has got its inherent deficiencies,
several limitations like fading, increased application and
releasing time, limitation in train length for maintenance of
vacuum levels in engine and brake van etc. In particular the
vacuum braked trains running on critical section with higher
altitudes are most inerrable since it is not possible solution is
to switch over to air brakes to have reliable and effective
brake power irrespective of the altitudes of the section,
distance covered, load and length of the train.
o TYPES OF AIR BRAKE
1) Direct release air brake
2) Graduated release air brake
 Direct release air brake
In this distributor valve does not allow the pressure in the
brake cylinder to be reduced by steps or stages. Increases in
this brake pipe pressure by steps have no bearing on the
exhaustibility of the brake cylinder pressure. When once the
exhaustibility of the brake cylinder pressure starts, it

26. continuous till it is vented out completely. This inherent
exhaustibility feature will be adversely affect the brake
cylinder pressure during the subsequent brake application.
 Graduated release air brake
The brake is effective on all the vehicles in a train and may be
graduated on and off in small steps under the control of a
drivers brake valve. The distributor valve allows the pressure
in the brake cylinder to be reduced by steps or stages. This
inherent in exhaustibility feature will facilitate in locking up
the air pressure in brake cylinder in cyclic brake
applications. This will help the driver to have an effective
control on transvers deseeding sustained step gradient
irrespective to repeated brake application.
Graduated release air brakes are two types:-
1) Single pipe graduated release
2) Double pipe graduated release

27. o WORKING PRINCIPLE
The brake pressure of all wagons are to be connecting with
flexible air hoses and then to the locomotive brake pressure.
All angle cock is to be kept open except front angle cock of
lending loco, and rear end of angle cock of brake van. Isolating
cocks on all wagons are to be kept open. The feed pipe of all
wagons are to be kept open the flexible air hoses provided with
opposite design of palm end and then to be locomotive main
reservoir pipe. All angle cocks of feed pipe are to be kept open
except from angle cock of the leading locomotive and the rear
angle cock of brake van. Isolating cock provided between FP
and rear side of auxiliary reservoir and to be kept open.

28. LHB COACH
Linke Hofmann Busch (LHB) coaches are the passenger
compartments of Indian Railways that have been developed by
Linke-Hofmann-Busch of Germany (renamed Alstom LHB
GmbH in 1998 after the takeover by Alstom) and produced by
Rail Coach Factory in Kapurthala, India.They have been used
since 2000 on the Indian Broad Gauge (1676 mm) network of
Indian railways. Initially, 24 air conditioned coaches were
imported from Germany for use in the Shatabdi Expresses, after
which the Rail Coach Factory started manufacturing after
technology transfer. The coaches are designed for an operating
speed up to 160 km/h and could go up to 200 km/h. However,
they have been tested up to 180 km/h. Their length of 23.54 m
and a width of 3.24 m means a higher passenger capacity,
compared to conventional rakes (US: consists).The tare weight
of the AC chair car was weighed as 39.5 tonnes.

29. -: BOGIE FRAME :-
The frameis made up of two longitudinalcomponents
(1) connectedby two cross-beams(2) which also
support thebrake units.The various supportswhich
connect the differentbogiecomponentsare welded to
the frame.

30. THANK YOU