industrial training in izzatngar workshop bareilly

1. Introduction to indian railways
INDIAN RAILWAYS IS AN ENTERPRISE OWNED AND OPERATED BY GOVERNMENT OF INDIA THROUGH THE
MINISTRY OF RAILWAYS. IT IS THE SECOND LARGEST RAILWAY NETWORK IN WORLD, COMPRISING OF
115,000 KM OF TRACK OVER A ROUTE OF 65,436 KM AND 7,172 STATIONS. IN 2015-16 INDIAN RAILWAYS
CARRIED MORE THAN 23 MILLION PASSENGERS EVERYDAY AND ALSO 1050.18 MILLION TONS OF FREIGHT
IN THE SAME YEAR.
RAILWAYS WERE FIRSTLY INTRODUCED IN INDIA IN THE YEAR 1853 FROM MUMBAI TO THANE. LATER ON IT
WAS NATIONALIZED AS INDIAN RAILWAYS AND BECOME SECOND LARGEST NETWORK IN THE WORLD.
INDIAN RAIL SYSTEMS WORK ON A MULTI GAUGE NETWORK NAMELY, BROAD GAUGE, METRE GAUGE AND
SMALL GAUGE.
INDIAN RAILWAYS IS SEVENTH LARGEST COMMERCIAL OR UTILITY BY NO OF EMPLOYEES WITH OVER 1.307
MILLION EMPLOYEES . INDIAN RAILWAYS ALSO OWNS 239,281 FREIGHT WAGONS , 62924 PASSENGER
COACHES AND 9.013 LOCOMOTIVES. TRAINS HAVE A DIGIT NUMBERING SYSTEM AND THERE RUNS 12,617
PASSENGER TRAINS , 7421 FREIGHT TRAINS DAILY (AS OF 31 MARCH 2013.)

2. MECHANICAL WORKSHOP
IZZATNAGAR
THE RAILWAY STATION IT HOUSES IS ONE OF DIVISIONAL HEADQUATOR OF
NE RAILWAYS.
IZZAT NAGAR RAILWAY MECHANICAL WORKSHOP WAS ESTABLISHED IN YEAR
1913 UNDER BRITISH RULE.
IZZAT NAGAR IS NAMED AFTER SIR ALEXENDER IZAT(1844-1920) , A SCOTTISH
ENGINEER AND DIRECTOR OF THE BENGAL AND NORTH WESTERN RAILWAY.
HE SPECIALIZED IN BRIDGE ENGINEERING AND CAME TO IZATNAGAR IN 1896.

3. LIST OF VARIOUS SHOPS
 AIR BRAKE SHOP
 SMITHY SHOP
 FABRICATION SHOP
 CARRIAGE REPAIR SHOP
 PAINT SHOP
 WHEEL SHOP

4. Total area of the workshop 455700 sq metres
Covered area 72056 sq. metres
Total length of MG track inside workshop 12 km
Total length of roads inside workshop 6.75 km
Standby power house installed capacity 600KW+350KW
Installed pneumatic power supply 95 cubic m/min
Average power consumption per month 115016 kwh
Average water consumption per day 130 K lit
Number of machines Installed 529
INFRASTRUCTURE AVAILABLE
AT WORKSHOP

5. Air brake shop
Braking is defined as the process of reducing the speed of any moving body or to
completely stop it. Braking is an essential component in railways to stop vehicles
at any point in need of emergency or whenever required.
Braking process is based on principle of friction , when brakes are applied then
there is a rubbing between brake shoe and wheel causing frictional loss and hence
loss of kinetic energy.
In Railways there are two types of braking system:
 Air-Braking system
 Vacuum-Braking system

6. Air Braking System:
This is a new method of braking system and is more efficient than vacuum
braking system. It is used firstly in Rajdhani and Shatabdi coaches. But progress
conversion of vacuum braking system in Air braking has been undertaken..
Now a days almost all coaches have air braking system and are working
efficiently.
The working flow diagram of Air braking system in railways is as shown in
next slide

9. The components of Air braking system are:
 BRAKE CYLINDER
There are two 355mm dia brake cylinder under frame , which is fed by common distributor valve. It has the piston rod
arrangement , which works under pressure . Brake cylinder is connected to distributer valve on one side and by pivot to
block cylinder.
 BRAKE PIPE
This is charged from the locomotive at 5 kg/cm2 and causes the application and release of brake due to change in pressure
through the locomotive control system. The pipes are linked to the distributor system.
 FEED PIPE
It is connected to the 6 kg/m2 pressure and keeps the auxillary reservoir charge at fule pressure even when brakes are
applied. Feed pipes are also connected to the distributor valve.

10.  DISTRIBUTER VALVE
it is connected to brake pipe auxillary reservoir and brake cylinder. It controls the pressure in the brake cylinder
in proportion to reduction of pressure in Brake pipe.
 ANGLE COCK
It is used for alarming purpose. When pressure in any component or in any line exceeds the safe limit then it
works by releasing pressure.
 HOUSE COUPLING
Both the brake pipe and feed pipe ar fitted to the angle cock outlet for the passenger compressed air from one
coach to another mean of braided rubber and metal coupling.

11.  GUARD VAN VALVE & PRESSURE GAUGE
These are provided in the guards compartments. These are provided to control the train
movement.
 ISOLATING COCK
Used for isolating the air from one point to the other point.
 CHOKE
It is a device for restructing the flow of air from one point brakes circuit to another point.
The handle of this cock is kept parallel to pipe ti indicate that it is in open conditions.

12. Smithy shop
Smithy shop in workshop consist of two works
 Testing of springs
 Sheet metal work
 Phosphating of items
Spring testing
Springs are the most useful and important part or component of bogie.
Springs are subjected to continuous load and are vulnerable of being damaged or being waste.
Hence railways continuously check the condition of the springs by making some series of tests and by classifying springs
on the basis of load carrying capacity and spring action.

13. PROCESS OF TESTING OF SPRING:
1. Arrival of springs from carriage lifting shop.
2.Cleaning in bosch tank.
3.Shot ballasting in air less centrifugal
and shot ballasting plant
4. Visual checking.

14. 5. Load testing on helical coil load testing machine.
6.Loop binding on
spring

15. 7.Coating of black Japanese paint on spring.
8.Grouping of spring into A ,B and C group according to load carrying
capacity

16. Thank you