1. Coach Care Center
Industrial Training
Project Report
Welcome to the Coach Care Center located in Old Delhi Railway Station.
This report covers the maintenance and repair work carried out in the
workshop.
by Deepak Kumar Sah
2. Acknowledgment
Training Provider
Indian Railways Institute of
Mechanical and Electrical
Engineering
Corporate Guide
Mr. Rakesh Kumar, Senior Section
Engineer - Carriage Workshop, Old
Delhi Railway Station
Project Guide
Mr. Ram Singh, Junior Engineer -
Coach Maintenance
Project Trainees
Akash Sharma
Harshita Singh
Shreya Jain
3. Introduction to Coach Care Center
Coach Care Center is the workshop where maintenance and repair work is carried out on trains and coaches. It ensures the safety and
reliability of railway transportation.
Maintenance
Regular maintenance of coaches is carried out to avoid any
sudden technical issues during travel.
Repair Work
In case of any damage or defects found in coaches, they are
immediately taken to the workshop for repair and maintenance.
4. Sick Line and its Importance
Sick Line is the section of the workshop where coaches with defects or damage are kept for repair. It is important to have a proper
Sick Line to ensure efficient maintenance and minimal downtime.
Types of Defects
Often, coaches have defects
related to brakes, wheels, doors, or
electrical systems.
Detection
Sick Line is the place where the
defects are first detected and
diagnosed by experts.
Repair and Maintenance
Coaches are repaired and
maintained until they comply with
the railway's safety regulations.
Return to Service
Once all defects are fixed, the coaches are thoroughly checked and returned to service.
5. Different Types of Maintenance
There are different types of maintenance carried out in the Coach Care Center depending on the level of repair required for the coach.
1 Preventive Maintenance
Preventive maintenance is carried out on a regular basis,
often monthly, to maintain the coaches' performance and
avoid unexpected breakdowns.
2
Predictive Maintenance
Predictive maintenance uses data analytics and
technological tools to detect potential problems and take
corrective actions before the issues become serious. 3 Craft Maintenance
Craft maintenance is performed as per the rules and
regulations laid down by the Indian Railways, and applies to
all types of trains and coaches.
4
Replacement Maintenance
Replacement maintenance involves replacing parts and
components that have surpassed their useful life or have
been too severely damaged.
6. Intermediate Overhauling
Intermediate Overhauling is a detailed maintenance process carried out on coaches after they have run for a certain number of kilometers. It
involves disassembling various parts of the coach to inspect and clean them thoroughly.
Inspection and Disassembly
Various parts of the coach, such as
underframe equipment, suspension system,
and brake system, are disassembled and
inspected for defects.
Cleaning and Lubrication
Components are cleaned, lubricated, and
repaired as per railway guidelines and
safety regulations.
Wheel Defects Gauge
Wheel defects are detected and corrected
using a wheel defects gauge and other
tools. Defective wheels are replaced.
7. Air Brake System and its Maintenance
The air brake system is a crucial component in any train or coach and its maintenance is crucial to ensure safe operations.
1
Inspection
The air brake system is inspected for leaks and any other
defects that can cause malfunctions.
2
Cleaning and Lubrication
The air brake parts are cleaned and lubricated to ensure
smooth operation.
3
Testing
The system is tested for proper functioning and
adjustments are made where necessary.
8. Bogie Mounted Brake System
Bogie Mounted Brake System is a crucial aspect of braking in any train or coach and its maintenance is crucial to ensure safe
operations.
Components
BMBS has different parts like brake
block, brake shoes, brake cylinder
and actuation systems.
Inspection
System is inspected for leaks,
alignment and brake lining wear.
Cleaning and Lubrication
Parts are cleaned and lubricated to
make sure there is no rust formed
on the surface of the part and
ensure proper operation of parts.
Testing
The system is tested for proper functioning and adjustments are made where necessary.
9. M&P in Coach Maintenance
M&P stands for Materials and Processes and is an important aspect of Coach Care Center maintenance.
Materials
M&P includes the use of various materials like antirust paint,
lubricating oils, coolants and abrasive grains in maintaining the
coaches.
Processes
Different processes include measurements, cleaning, testing in
detecting any defects in coach during routine maintenance and
repair work.
10. Maintenance of Washing Line
Washing Line is the place where cleaning of coaches is done thoroughly.
Water Recycling Setup
Water used in cleaning is recycled
to reduce wastage of water.
Steam Cleaning
Steam cleaning is done to remove
stubborn dirt, grease and oil stains
from the surface of the coach.
Solar System
The Washing Line is powered by a
solar system that reduces
greenhouse gas emissions.
Human Resources
Skilled employees are trained to operate the Washing Line effectively and efficiently.
11. Suggestions for Improvement
To improve the functioning and efficiency of the Coach Care Center, the
following suggestions are offered:
• Training of coaches from scratch or testing and certifying new
coaches before rolling out for service.
• Upgrading the maintenance and repair equipment and tools to
reduce the downtime of coaches in Sick Line.
• Replacing the old brake system with better, more effective ones for
better braking efficiency.
• Enhancing communication channels and adopting better
technology to facilitate higher transparency and accuracy in
maintenance work.
