This show you how our railways working and the concept behind the EMU's , DEMU's and MEMU's cars in our country.

1. INDUSTRIAL TRAINING
REPORT
SUBMITTED BY :-
RAMESH KUMAR SHARMA
BRANCH – M.E
SECTION – B
I.T.S ENGINEERING COLLEGE
, GR.NOIDA

2. CONTENTS
. HISTORY
. INTRODUCTION OF EMU CAR SHED
. TYPES OF TRAINS IN EMU CAR SHED
. NO. OF SECTIONS
. MECHENICAL WORKSHOP
. COMPONENT MATERIALS
. BOGIE
. METALLURGICAL LAB
. MEASURING & INSPECTION
. TRACTION MOTOR
. TURBO SUPERCHARGER
. COMPRESSOR
. PIT WHEEL LATHE
. PENTOGRAPH

3. INDIAN RAILWAY
HISTORY
Indian Railways is the state-owned railway company of
India. It comes under the Ministry of Railways. Indian
Railways has one of the largest rail networks in the
world, transporting over 18 million passengers and
more than 2 million tonnes of freight daily. Its revenue
is Rs.107.66 billion. It is the world's largest
commercial employer, with more than 1.4 million
employees.

4. . It operates rail transport on 6,909 stations over a total route
length of more than 63,327 kilometers(39,350 miles).The fleet
of Indian railway includes over 200,000 (freight) wagons,
50,000 coaches and 8,000 locomotives. It also owns
locomotive and coach production facilities. It was founded in
1853 under the East India Company.
. Indian Railways is administered by the Railway Board.
Indian Railways is divided into 16 zones. Each zone railway is
made up of a certain number of divisions. There are a total
of sixty-seven divisions. It also operates the Kolkata metro.
There are six manufacturing plants of the Indian Railways.
The total length of track used by Indian Railways is about
108,805 km (67,608 mi) while the total route length of the
network is 63,465 km (39,435 mi).

5. •The broad gauge (1670 mm)
•The meter gauge (1000 mm)
•Narrow gauge (762 mm)
•Narrow gauge (610 mm).
Indian Railways operates about 9,000 passenger trains and
transports 18 million passengers daily .Indian Railways makes
70% of its revenues and most of its profits from the freight
sector, and uses these profits to cross-subsidies the loss-making
passenger sector. The Rajdhani Express and Shatabdi
Express are the fastest trains of India

6. CLASSIFICATION
. Standard “Gauge” designations and dimensions:-
W = Broad gauge (1.67 m)
Y = Medium gauge ( 1 m)
Z = Narrow gauge ( 0.762 m)
N = Narrow gauge ( 0.610m)
.“ Type of Traction” designations:-
D = Diesel-electric traction
C = DC traction
A = AC traction
CA=Dual power AC/DC traction
. The “ type of load” or “Service” designations:-
M= Mixed service
P = Passenger
G= Goods
S = Shunting

7. . “ Horse power ” designations from June 2002 (except
WDP-1 & WDM-2 LOCOS)
‘ 3 ’ For 3000 horsepower
‘ 4 ’ For 4000 horsepower
‘ 5 ’ For 5000 horsepower
‘ A ’ For extra 100 horsepower
‘B’ For extra 200 horsepower and so on.
Hence ‘WDM-3A’ indicates a broad gauge loco with diesel-electric
traction. It is for mixed services and has 3100
horsepower.|~|

8. INTRODUCTION
EMU CAR shed is an industrial-technical setup, where
repair and maintenance works of EMU & DEMU is carried
out, so as to keep the loco working properly. It
contributes to increase the operational life of EMU &
DEMU and tries to minimize the line failures.

9. . The shed consists of the infrastructure to berth, dismantle,
repair and test the loco and subsystems. The shed working is
heavily based on the manual methods of doing the maintenance
job and very less automation processes are used in sheds,
especially in India.
The EMU CAR shed usually has:-
 Berths and platforms for loco maintenance.
 Pits for under frame maintenance
 Heavy lift cranes and lifting jacks
 Fuel storage and lube oil storage, water treatment plant
and testing labs etc.
 Sub-assembly overhauling and repairing sections
 Machine shop and welding facilities.

10. TYPES OF TRAINS IN
EMU CAR SHED
There are three trains are inspection and maintenance in
EMU CAR shed. These are as follow :-
1. EMU
2. MEMU
3. DMU

11. EMU & MEMU

12. 1. EMU – In EMUs one power car (motor coach) is required
for three coaches so for an EMU has 12 coaches in length
will have 4 power cars & mainly runs in the suburban
sections of major cities. It considered as normal local
trains such as life line locals of MUMBAI, HYDERABAD,
CHENNI etc
2. MEMU’s – In MEMUs one power car in needed for 4
coaches so MEMU are normally has 16-20 coaches long. It
runs for long distance more than the suburban sections .
It runs on the same line on which normal
Local/Exp/Mail/SF trains runs.
MEMU – Vadodara – Ahmadabad MEMU
MEMU were modified EMU’s introduced in 1993-94
3. DEMU’s – In DEMU’s , generally runs on diesel which
tank capacity about >4000lts. It named as overhead
electric inspection car used in repair & maintenance of
overhead cables which fitted above the roof of trains
carries 25kv A.C supply.

13. SPECIFICATIONs:-
• Compressor - 8kg/cm2
• Engine type – V type engine, clockwise rotation
• Lubricant used – servo plex TM-3 , servo press 150
• Fire order -
1L-6R-2L-5R-4L-3R-6L-1R-5L-2R-3L-4R

14. NO. OF SECTIONS
•1 . MECHANICAL WORKSHOP
•2 . ELECTRICAL WORKSHOP
•3 . PAINTING WORKSHOP

15. MECHANICAL WORKSHOP
1. MEASUREMENT & INSPECTION SHOP
2. CARPENTARY SHOP
3. PENTOGRAPH SHOP
4. MACHINE SHOP
5. J.S.L TYPE BRAKE CYLINDER SHOP
6. POH SHOP
7. TRANSMISSION SHOP
8. COMPRESSOR SHOP

16. COMPONENT MATERIALS
AXLE – alloy’s
0.5 – 0.6 % C
0.8 – 1.0 % Mn
0.35 % Cr
0.7 % Mo
BRAKE BLOCK – Ferobestos
It has crushing strength about 1.3 tones
Density – (1.95- 2.05 ) gm/m3

17. BOGIE

18. BOGIE’s
A BOGIE is a wheeled wagon or trolley. In mechanics
terms, a bogie is a frame work which carrying wheels
attached to coaches.
It is subassembly of 2 axle, 4 wheel, 4 jsl type brake
cylinder , 2 side bearer, 4 bearing(double roller bearing),
helical spring etc

19. METALLURGICAL LAB
Metallurgical lab. concern with the study of material
composition and its properties. Specimens are checked for its
desired composition. In this section various tests are conducted
like hardness test, composition test e.g. determination of
percentage of carbon, swelling test etc.

20. Function of some of the metal is tabulated in table below :-
S.No. Compound Function
1. Phosphorous - Increase the fluidity property
2. Graphite - Increase machinability
3. Cementide - Increase hardness
4. Chromium - Used for corrosion prevention
5. Nickel - Used for heat resistance
6. Nitride rubber - Oil resistance in touch of ‘O’ ring
7. Neoprene - Air resistance & oil resistance in fast
coupling in rubber block
8. Silicon - Heat resistance and wear resistance
(upto 600 ºC ) use at top and bottom pore
of liner.

21. Swelling test
Swelling test is performed for rubber in this test percentage increase in
weight of the rubber after immersing in solution is measured and increase
in weight should not be more than 20%. Two type of swelling test viz low
swelling and high swelling are performed in the lab. Three type of oil
solution are used for this purpose listed below:-
• ASTM 1
• ASTM 2
• ASTM 3
Procedure
1. Select specimen for swelling test
Note the weight of the specimen
Put in the vessel containing ASTM 1 or ASTM 3
Put the oven at 100 ºC
Put the vessel in the oven for 72 hrs.
After 72 hrs. Weigh the specimen.

22. Rubber
Broadly there are two types of rubber:
1). Natural rubber- this has very limited applications. It is used
in windows and has a life of 1 year.
2). Synthetic rubber- this is further subdivided into five types.
• VUNA-N (2 year life)
• Polychloroprene or Neoprene (2 year life)
• SBR (3 year life)
• Betel (3 year life)
• Silicone (3 year life).

23. ULTRASONIC TESTING
• In ultrasonic testing, very short ultrasonic pulse-waves with center frequencies ranging
from 0.1-15 MHz and occasionally up to 50 MHz are launched into materials to detect
internal flaws or to characterize materials.
•Ultrasonic testing is often performed on steel and other metals and alloys,
though it can also be used on concrete, wood and composites, albeit with less
resolution. It is a form of non-destructive testing .
RED DYE PENETRATION TEST (RDP)
Dye reentrant inspection (DPI), also called liquid reentrant
inspection (LPI), is a widely applied and low-cost inspection method
used to locate surface-breaking defects in all non-porous materials
(metals, plastics, or ceramics). Reentrant may be applied to all non-ferrous
materials, but for inspection of ferrous components magnetic
particle inspection is preferred for its subsurface detection capability.
LPI is used to detect casting and forging defects, cracks, and leaks in
new products, and fatigue cracks on in-service components.

24. Principles
•DPI is based upon capillary action, where low surface
tension fluid penetrates into clean and dry surface-breaking
discontinuities. Reentrant may be applied to the test
component by dipping, spraying, or brushing.
•After adequate penetration time has been allowed, the
excess reentrant is removed, a developer is applied. The
developer helps to draw reentrant out of the flaw where a
visible indication becomes visible to the inspector.

25. MEASURING & INSPECTION

26. TYRE DEFECT GUAGE
1. Root wear
2. Sharp flange
3. Thin flange
4. Deep flange
5. Hollow tyre
6. Flat tyre (tyre condum)

27. TRACTION MOTOR

28. TRACTION
MOTOR
Traction motor refers to
an electric motor providing
the primary rotational torque
to a machine, usually for
conversion into linear
motion (traction).
Traction motors are used in
electrically powered rail
vehicles such as electric
multiple units and electric
locomotives, other electric
vehicles such as electric milk
floats, elevators, conveyors,
and trolleybuses, as well as
vehicles with electrical
transmission systems such
as diesel-electric,
electric hybrid
vehicles and battery electric
vehicles

29. TURBO SUPERCHARGER

30.  The diesel engine produces mechanical energy by converting
heat energy derived from burning of fuel inside the cylinder.
 A turbocharger or turbo, is a gas compressor used for forced-induction
of an internal combustion engine. Like a
supercharger, the purpose of a turbocharger is to increase the
density of air entering the engine to create more power.
However, a turbocharger differs in that the compressor is
powered by a turbine driven by the engine's own exhaust
gases.
 The maximum rotational speed of the turbine is 18000/22000
rpm for the Turbo supercharger and creates max. Of 1.8
kg/cm2 air pressure in air manifold of diesel engine, known as
Booster Air Pressure (BAP). Low booster pressure causes black
smoke due to incomplete combustion of fuel. High exhaust gas
temperature due to after burning of fuel may result in
considerable damage to the turbo supercharger and other
component in the engine.

31. TURBO SUPERCHARGER AND ITS WORKING PRINCIPLE
 The exhaust gas discharge from all the cylinders accumulate in the common
exhaust manifold at the end of which, turbo- supercharger is fitted. The gas under
pressure there after enters the turbo- supercharger through the torpedo shaped bell
mouth connector and then passes through the fixed nozzle ring. Then it is directed on
the turbine blades at increased pressure and at the most suitable angle to achieve
rotary motion of the turbine at maximum efficiency. After rotating the turbine, the
exhaust gas goes out to the atmosphere through the exhaust chimney. The turbine has
a centrifugal blower mounted at the other end of the same shaft and the rotation of
the turbine drives the blower at the same speed. The blower connected to the
atmosphere through a set of oil bath filters, sucks air from atmosphere, and delivers at
higher velocity. The air then passes through the diffuser inside the turbo- supercharger,
where the velocity is diffused to increase the pressure of air before it is delivered from
the turbo- supercharger.

32. MAIN COMPONENTS OF TURBO-SUPERCHARGER

Turbo- supercharger consists of following main components:-
1. Gas inlet casing.
2. Turbine casing.
3. Intermediate casing
4. Blower casing with diffuser
5. Rotor assembly with turbine and rotor on the same shaft.

33. ADVANTAGES OF SUPER CHARGED ENGINES
• A super charged engine can produce 50 percent or more power
than a naturally aspirated engine. The power to weight ratio in
such a case is much more favorable.
• Better scavenging in the cylinders. This ensures carbon free
cylinders and valves, and better health for the engine also.
• Better ignition due to higher temperature developed by higher
compression in the cylinder.
• It increases breathing capacity of engine.
• Better fuel efficiency due to complete combustion of fuel

34. Defect in Turbochargers
1. Low Booster Air Pressure (BAP).
2. Oil throwing from Turbocharger because of seal damage or out
of clearance.
3. Surging- Back Pressure due to uneven gap in Nozzle Ring or
Diffuser Ring.
Must change components of Turbocharger.
 Intermediate casing gasket.
 Water outlet pipe flange gasket.
 Water inlet pipe flange gasket.
 Lube Oil inlet pipe rubber ‘o’ ring.
 Turbine end Bearing.
 Blower end Bearing.
 Chimney gasket.
 Rubber ‘o’ Ring kit.
 Spring Washers.
 Lock Washer Rotor Stud.

35. COMPRESSOR

36. COMPRESSOR
The compressor is a two stage compressor with one low pressure
cylinder and one high pressure cylinder. During the first stage of
compression it is done in the low pressure cylinder where suction
is through a wire mesh filter. After compression in the LP cylinder
air is delivered into the discharge manifold at a pressure of 30 / 35
PSI. Workings of the inlet and exhaust valves are similar to that of
exhauster which automatically open or close under differential air
pressure. For inter-cooling air is then passed through a radiator
known as inter-cooler and than this compressed air passes to high
pressure cylinder and stored in auxiliary and brake cylinder for brake
application. Such as :
BRAKES:
 Emergency brake – (7kg from M.R)
 Auto brake – (5kg from B.P)
 Guard brake – (E.P+AUTO)
 Dead man brake – 5kg
 Electric pneumatic brake – 5kg

37. PIT WHEEL LATHE

38. INTRODUCTION
Various type of wear may occur on wheal tread and flange due to
wheel skidding and emergency breaking. Four type of wear may
occur as follows:-
• Tread wear
• Root wear
• Skid wear and
• Flange wear
For maintaining the required profile pit wheel lathe are used. This
lathe is installed in the pit so that wheel turning is without
disassembling the axle and lifting the loco and hence the name “pit
wheel lathe”

39. Wheel turning
Wheel turning on this lathe is done by rotating the wheels, both
wheels of an axle are placed on the four rollers, two for each wheel.
Rollers rotate the wheel and a fixed turning tool is used for turning
the wheel.

40. PENTOGRAPH

41. PANTOGRAPH
Pantograph is an apparatus which mounted on the roof of the
electric train to collect power through contact with an overhead
tension wire. It lift or down on the basis of wire tension.
Typically a single wire is used with the return current running
through the track.
Device used to control it :-
• Servomotor (4.6kg/cm2)
• VCB/ABB
WORKING SPECIFICATIONS:
• WORKING TIME – (6-10)second but it takes 12 min.
• LEAKAGE TESTING – 7kg

42. PANTOGRAPH PARTS :
• Base
• Lower arm
• Main spring
• Centre pedestal
• Balancing beam
• Longitudinal tube
• Steady link
• Steady tube
• Push rod
• Middle articulation
assembly
• Upper articulation
assembly
• Bow assembly
• Yog assembly
• Copper shunt
• Metalize carbon strip