This document is a summer training report submitted by Sachin Deora, a final year mechanical engineering student at V.I.E.T. Jodhpur, for his 50 day summer training at the Carriage Workshop of North Western Railway in Jodhpur. The report provides details of the various shops and work carried out at the workshop, including fitting, welding, carriage building and repair, lifting, trimming, corrosion repair, paint, brake gear, wheel, and other shops. It also includes an introduction to the workshop, salient features of Indian Railways, the training schedule, and hierarchy at the Jodhpur workshop.
indian railway gorakhpur training report for mechanical engineering 2016 Kishan Bharti
This document is an industrial training report submitted by Kishan Bharti during a 4-week training at the North Eastern Railway workshop in Gorakhpur, India. It includes an introduction to Indian Railways, a description of various shops in the workshop including machine, painting, wheel, spring, heat treatment, and jig and fixture shops. It also summarizes the processes, equipment, and activities carried out in each shop during Kishan's training period at the workshop.
This document is an industrial training report submitted by Sumit Kumar from the Institute of Engineering & Management in Kolkata. It describes his 15-day summer training at the Carriage and Wagon Workshop of the Northeast Frontier Railway in New Bongaigaon, Assam. The report provides details about the workshop, including its history and activities. It also describes several shops within the workshop such as the wheel turning shop, roller bearing shop, machine shop, and others. In each shop, it outlines the key machines and operations.
This document provides details about an internship training project conducted at the Central Railway Locomotive Workshop in Parel, Mumbai. It includes an introduction, certificates of completion for three interns, an acknowledgment, an index of topics covered in the internship report, and initial sections on braking systems used in Indian railways. Specifically, it discusses the classification of braking systems, focusing on air brake systems which use compressed air supplied by air compressors to activate brakes on each coach through a series of pipes, reservoirs, valves and cylinders.
Training report on railways (all workshop)anand prasad
The document discusses corrosion in Indian railway coaches. Corrosion is a major problem that reduces structural integrity and needs to be addressed during periodic overhauls. Key areas prone to corrosion include sole bars, body pillars, turn unders, and areas below lavatories. During overhauls, all underframe members are inspected for corrosion and repaired using approved steel sheets, electrodes, primers, and other treatments as specified by standards.
Central Railway Locomotive Workshop in Parel, Mumbai provides inplant training. This report details the training of Akshay Ghanwat and Satish Ghatge during the 2015-16 academic year. It describes the various shops in the workshop including the machine shop with lathes, CNC machines, and tools. It also discusses the wheel shop, welding shop, diesel locomotives, narrow gauge locomotives, and cranes.
The document provides information about Pradeep Vyas's practical training at the Northern-Western Railway Workshop. It discusses the various shops within the workshop including the power shop, air conditioning shop, train lighting shop, and production and control department. It describes the key equipment and processes used in each shop's operations for maintaining railway equipment. The workshop provides basic training to engineering graduates and technicians to develop their skills.
The document is a training report on an air brake system submitted by Vishal Singh from GB Pant Engineering College. It includes an acknowledgement, table of contents, and sections on the brief about the training, classification of engines, introduction to the diesel loco shed, directly assisting sections, and a project study on air brake systems. The project study section includes introductions to straight air brakes and working pressures, descriptions of operations and types of air brake systems like 28 LAV 1 and IRAB 1 used on Indian Railways locomotives, and explanations of components like the expressor, distributor valve, and types of valves. It discusses overhauling procedures, potential issues like brake binding, and developments in other countries.
This document is the Maintenance Manual for Wagons published by the Ministry of Railways in India in December 2015. It provides guidelines for the maintenance of various systems of wagons, including the superstructure, running gear, braking system, etc. The manual aims to be a single reference document for maintenance of wagons in workshops and depots. It covers maintenance instructions for different types of currently used wagons in India and lists rules from other rulebooks as a supplemental reference. Technological upgrades are ongoing, so separate instructions will be issued as new wagon designs are introduced.
indian railway gorakhpur training report for mechanical engineering 2016 Kishan Bharti
This document is an industrial training report submitted by Kishan Bharti during a 4-week training at the North Eastern Railway workshop in Gorakhpur, India. It includes an introduction to Indian Railways, a description of various shops in the workshop including machine, painting, wheel, spring, heat treatment, and jig and fixture shops. It also summarizes the processes, equipment, and activities carried out in each shop during Kishan's training period at the workshop.
This document is an industrial training report submitted by Sumit Kumar from the Institute of Engineering & Management in Kolkata. It describes his 15-day summer training at the Carriage and Wagon Workshop of the Northeast Frontier Railway in New Bongaigaon, Assam. The report provides details about the workshop, including its history and activities. It also describes several shops within the workshop such as the wheel turning shop, roller bearing shop, machine shop, and others. In each shop, it outlines the key machines and operations.
This document provides details about an internship training project conducted at the Central Railway Locomotive Workshop in Parel, Mumbai. It includes an introduction, certificates of completion for three interns, an acknowledgment, an index of topics covered in the internship report, and initial sections on braking systems used in Indian railways. Specifically, it discusses the classification of braking systems, focusing on air brake systems which use compressed air supplied by air compressors to activate brakes on each coach through a series of pipes, reservoirs, valves and cylinders.
Training report on railways (all workshop)anand prasad
The document discusses corrosion in Indian railway coaches. Corrosion is a major problem that reduces structural integrity and needs to be addressed during periodic overhauls. Key areas prone to corrosion include sole bars, body pillars, turn unders, and areas below lavatories. During overhauls, all underframe members are inspected for corrosion and repaired using approved steel sheets, electrodes, primers, and other treatments as specified by standards.
Central Railway Locomotive Workshop in Parel, Mumbai provides inplant training. This report details the training of Akshay Ghanwat and Satish Ghatge during the 2015-16 academic year. It describes the various shops in the workshop including the machine shop with lathes, CNC machines, and tools. It also discusses the wheel shop, welding shop, diesel locomotives, narrow gauge locomotives, and cranes.
The document provides information about Pradeep Vyas's practical training at the Northern-Western Railway Workshop. It discusses the various shops within the workshop including the power shop, air conditioning shop, train lighting shop, and production and control department. It describes the key equipment and processes used in each shop's operations for maintaining railway equipment. The workshop provides basic training to engineering graduates and technicians to develop their skills.
The document is a training report on an air brake system submitted by Vishal Singh from GB Pant Engineering College. It includes an acknowledgement, table of contents, and sections on the brief about the training, classification of engines, introduction to the diesel loco shed, directly assisting sections, and a project study on air brake systems. The project study section includes introductions to straight air brakes and working pressures, descriptions of operations and types of air brake systems like 28 LAV 1 and IRAB 1 used on Indian Railways locomotives, and explanations of components like the expressor, distributor valve, and types of valves. It discusses overhauling procedures, potential issues like brake binding, and developments in other countries.
This document is the Maintenance Manual for Wagons published by the Ministry of Railways in India in December 2015. It provides guidelines for the maintenance of various systems of wagons, including the superstructure, running gear, braking system, etc. The manual aims to be a single reference document for maintenance of wagons in workshops and depots. It covers maintenance instructions for different types of currently used wagons in India and lists rules from other rulebooks as a supplemental reference. Technological upgrades are ongoing, so separate instructions will be issued as new wagon designs are introduced.
1. Indian Railways is a state-owned railway system that operates the seventh largest commercial network in the world. It transports over 8 billion passengers annually on a network spanning over 115,000 km.
2. In the mid-19th century, the first railway lines in India were built under British colonial rule. By 1880, the railway network had expanded to about 14,500 km, connecting major port cities.
3. To improve passenger comfort and safety, Indian Railways introduced LHB coaches designed by German company Linke-Hofmann-Busch in 2001. Key advantages of LHB coaches include higher speed potential, lower maintenance costs, and better riding quality compared to older ICF coach designs.
Summer Internship/Training report at Indian RailwayChirag Jain
The document summarizes Chirag Jain's 15-day summer training at the Western Railway Carriage Repair Workshop in Mumbai. It includes an acknowledgement, declaration, preface, and schedule of shops visited each day including lifting and maintenance of ICF and FIAT bogies, suspension springs and shock absorbers, air brake systems, wheels and axles, and final inspection. Key activities of the workshop included periodic overhauling of 1500 passenger coaches per year. Maintenance processes for bogies, air brakes, and other components are described. Safety precautions and defects to check for during maintenance are also outlined.
Indian railways mechanical vocational training report 1 haxxo24 i~ihaxxo24
Indian Railways was previously transporting passengers using coaches designed by ICF that had limitations in speed, corrosion resistance, ride comfort, and part wear. To address this, it began procuring LHB coaches from Alstom featuring superior passenger experience, safety, and maintenance needs. Key benefits of LHB coaches include higher capacity, lower weight, reduced corrosion, lower maintenance requirements, and improved aesthetics, comfort, and safety. They use advanced materials, designs, and manufacturing techniques.
This document provides a summary of a training report presentation on the Carriage & Wagon Workshop in Jagadhri. It introduces the workshop, describing its founding in 1952 and responsibilities of repairing rolling stock. It then describes some of the main shops on the workshop including bogie, wheel, and paint shops. It further discusses the lifting shop and how rolling stock is assembled and parts introduced. It classifies different types of rolling stock and describes braking systems, focusing on vacuum and air brakes including their principal parts and operations in release, application, and lap stages. CNC plasma cutting is also introduced.
This internship report summarizes the work done during an internship at the Mughalpura Railway Works in Lahore, Pakistan. The internship provided hands-on experience in various workshops including the diesel classified shop, foundry shop, E & DC shop, and spring shop. Key activities included learning about locomotive parts and operations, inspecting production processes, and understanding maintenance schedules. The report describes the functions of each workshop and manufacturing processes like casting, machining, and spring production. It aims to connect theoretical knowledge to practical applications in the railway industry.
The document provides an overview of the process of mid-life rehabilitation (MLR) of railway coaches at the Coach Rehabilitation Workshop in Bhopal, India. The MLR process involves completely stripping and repairing coaches that are 12-15 years old. Key steps include separating the bogie and shell, stripping components to identify corrosion, heavy corrosion repair, painting, refurbishing interior furnishings, and reassembling. Specialized shops support each step of the process, from lifting and stripping, to body repair, painting, carpentry works, and reinstallation of components. Upon completion, coaches undergo testing before returning to service with an "as new" condition.
The document provides an introduction and overview of the updated Indian Railways Unified Maintenance Manual for Wagons. Some key points:
- The previous maintenance manual was published in 1979 and did not cover air brake systems, which have since been introduced.
- A committee was formed in 1998 to revise and update the manual to reflect modern wagon designs, maintenance strategies, and technological upgrades across Indian Railways.
- The updated manual provides comprehensive maintenance instructions for all wagon systems, with a focus on air brake systems. It is intended to serve as a single reference for wagon maintenance.
- Standardized numbering conventions are used for chapters, paragraphs, figures and tables to facilitate future revisions as new stock is introduced.
SUMMER TRAINING PPTOnCoach Care Centre (SICK LINE) Amit Verma
This document discusses the maintenance schedules and processes for different types of coaches in India. It provides the following key details:
1. Coaches are classified as minor, medium or major depending on their capacity of 50-100, 100-250, or above 250 passengers respectively.
2. Maintenance depots are categorized as integral coach factory (ICF), rail coach factory (RCF), link holfmann bushh (LHB), or hybrid depending on the coach design and components.
3. Regular maintenance includes washing after every trip and sick line maintenance on monthly, quarterly, or six month schedules depending on the coach category.
4. The sick line workshop performs repairs and overhauls like
The document provides information about Indian Railways and the North Western Railway zone. It discusses the Mechanical Department which oversees maintenance of rolling stock. It then summarizes the Ajmer Railway Workshop and Carriage Workshop, noting their history and roles in maintaining coaches. The document outlines different types of train maintenance including primary, turnaround, and secondary maintenance. It also describes maintenance schedules for coaches including A-Schedule, B-Schedule and periodic overhauling.
Jhansi Workshop is the biggest Wagon Repair Workshop of Indian Railways. It is
spread in area of 3.4 lakh square meter. The Covered area is 65000 square meter. The
Railway Board Wagon POH target for Jhansi workshop is 610 wagons per month which is
approximately 16 % of the wagon POH done in Indian Railways.
The document is an industrial training report on diesel locomotive technology submitted by Shivam Prajapati. It includes an acknowledgement, contents listing the topics covered in the report such as the introduction of Indian Railways, diesel locomotive shed in Charbagh, diesel electric locomotive components, fuel section, lube oil control section, turbosupercharger, fuel oil pump, bogie, air brake, traction motor, generator, power pack, and failure analysis. It also includes diagrams to illustrate parts of the locomotive like the fuel tank and turbosupercharger.
Summer Training Report on Indian Railways , C& W Workshop, NBQ, AssamDeepjyoti Patowary
This project report is based on Indian Railways Carriage and Wagon Workshop, New Bongaigaon, Assam under North-East Frontier (NFR) Railways. Project is uploaded here only based on educational purpose which will help the students studying engineering and undergoes industrial training. It may have some doubtful information. Readers are asked to re-verify the pieces of information before use.
The Northern Railways is one of the 16 zones and the northernmost zone of the Indian Railways. Its headquarter is New Delhi Railway Station.
Northern Railways is one of nine old zones of Indian Railways and also the biggest in terms of network having 6807 kilometre route.[1] It covers the states of Jammu and Kashmir, Punjab, Haryana, Himachal Pradesh, Uttarakhand and Uttar Pradesh and the Union territories of Delhi and Chandigarh.
This presentation provides an overview of the Carriage and Wagon workshop in Alambagh, India. It discusses the workshop's history and facilities for maintaining various types of passenger coaches. The major sections covered include bogie maintenance, suspension system maintenance, and the various coach types maintained at the workshop, from unreserved coaches to 1AC coaches. An overview is also provided of the key components of bogies, including wheels, springs, frames, and brakes.
This document provides details about Ashutosh Khaitan's six-week industrial training at the Coach Care Centre in Old Delhi railway station from June-July 2013. It includes a training schedule, acknowledgements, abbreviations used, and an introduction to the Coach Care Centre and its role in railway maintenance. The bulk of the document describes procedures for intermediate overhauling of coaches, air brake system maintenance and repair, brake down maintenance, and washing line maintenance.
I had done 1 month summer training on topic " AIR BRAKE SYSTEM USED IN LOCOMOTIVE " from LOCO workshop, LKO....students who are doing so....this file can help them to prepare project file...
This document provides information on different shops in a railway workshop, including the air conditioning shop, power shop, production control organization (PCO) shop, and train lighting shop. In the air conditioning shop sections, it describes the specifications and safety protections of roof mounted package units used for air conditioning trains. The power shop section outlines the substation and protective devices used. The PCO shop discusses the electrical inspections conducted on trains. Finally, the train lighting shop explains the fan and battery sections, including the types of fans and maintenance of lead acid and VRLA batteries.
G 80. inspection and maintenance of centre buffer couplers ( for workshop sta...SrinivasaRao Guduru
The document provides instructions for the inspection, maintenance, and reconditioning of centre buffer couplers. It outlines classification procedures and acceptance requirements for reconditioned parts. Parts can be reconditioned through processes like weld repair and heat treatment, to meet specified hardness levels. Detailed heat treatment procedures are provided for different steel grades. Inspection and maintenance is also described for components like draft gears, clevises and striker castings.
The Liluah Railway Carriage and Wagon Workshop in Howrah, West Bengal overhauls various types of coaches and wagons. It has different shops that perform maintenance like the L shop which handles four types of wagons, the LHB shop which maintains higher speed trains, and the M shop which does overhauls of ICF, BEML, and RCF coaches. The workshop also has facilities like the welding shop, corrosion treatment shop, calibration room, and performs tasks like shot blasting, load testing, and grading/color coding of parts.
The document provides a training report submitted by Anish Malan for his summer training at the Railway Workshop in Jagadhari. It includes an overview of the railway workshop, its organizational structure, production units, quality policies, safety measures followed, classification of rolling stock, important systems and components of rolling stock. It also describes various processes carried out in the wheel shop like boring, axle turning, axle grinding, tapping, wheel press operation, axle journal turning and burnishing, tyre turning. It discusses the zyglo test procedure for roller bearings and ultrasonic test for axles.
The document provides an overview of the Mechanical Workshop at North Eastern Railway in Gorakhpur, Uttar Pradesh. It describes the various shops within the workshop, including the Machine Shop, Shell Shop, Spring Shop, Bogie Shop, and Wheel Shop. The Machine Shop utilizes various types of computer numerical control machines like lathes, mills, drills to machine parts to the required specifications. The workshop oversees the repair and overhaul of railway coaches and aims to modernize its facilities and processes for increased efficiency.
1. Indian Railways is a state-owned railway system that operates the seventh largest commercial network in the world. It transports over 8 billion passengers annually on a network spanning over 115,000 km.
2. In the mid-19th century, the first railway lines in India were built under British colonial rule. By 1880, the railway network had expanded to about 14,500 km, connecting major port cities.
3. To improve passenger comfort and safety, Indian Railways introduced LHB coaches designed by German company Linke-Hofmann-Busch in 2001. Key advantages of LHB coaches include higher speed potential, lower maintenance costs, and better riding quality compared to older ICF coach designs.
Summer Internship/Training report at Indian RailwayChirag Jain
The document summarizes Chirag Jain's 15-day summer training at the Western Railway Carriage Repair Workshop in Mumbai. It includes an acknowledgement, declaration, preface, and schedule of shops visited each day including lifting and maintenance of ICF and FIAT bogies, suspension springs and shock absorbers, air brake systems, wheels and axles, and final inspection. Key activities of the workshop included periodic overhauling of 1500 passenger coaches per year. Maintenance processes for bogies, air brakes, and other components are described. Safety precautions and defects to check for during maintenance are also outlined.
Indian railways mechanical vocational training report 1 haxxo24 i~ihaxxo24
Indian Railways was previously transporting passengers using coaches designed by ICF that had limitations in speed, corrosion resistance, ride comfort, and part wear. To address this, it began procuring LHB coaches from Alstom featuring superior passenger experience, safety, and maintenance needs. Key benefits of LHB coaches include higher capacity, lower weight, reduced corrosion, lower maintenance requirements, and improved aesthetics, comfort, and safety. They use advanced materials, designs, and manufacturing techniques.
This document provides a summary of a training report presentation on the Carriage & Wagon Workshop in Jagadhri. It introduces the workshop, describing its founding in 1952 and responsibilities of repairing rolling stock. It then describes some of the main shops on the workshop including bogie, wheel, and paint shops. It further discusses the lifting shop and how rolling stock is assembled and parts introduced. It classifies different types of rolling stock and describes braking systems, focusing on vacuum and air brakes including their principal parts and operations in release, application, and lap stages. CNC plasma cutting is also introduced.
This internship report summarizes the work done during an internship at the Mughalpura Railway Works in Lahore, Pakistan. The internship provided hands-on experience in various workshops including the diesel classified shop, foundry shop, E & DC shop, and spring shop. Key activities included learning about locomotive parts and operations, inspecting production processes, and understanding maintenance schedules. The report describes the functions of each workshop and manufacturing processes like casting, machining, and spring production. It aims to connect theoretical knowledge to practical applications in the railway industry.
The document provides an overview of the process of mid-life rehabilitation (MLR) of railway coaches at the Coach Rehabilitation Workshop in Bhopal, India. The MLR process involves completely stripping and repairing coaches that are 12-15 years old. Key steps include separating the bogie and shell, stripping components to identify corrosion, heavy corrosion repair, painting, refurbishing interior furnishings, and reassembling. Specialized shops support each step of the process, from lifting and stripping, to body repair, painting, carpentry works, and reinstallation of components. Upon completion, coaches undergo testing before returning to service with an "as new" condition.
The document provides an introduction and overview of the updated Indian Railways Unified Maintenance Manual for Wagons. Some key points:
- The previous maintenance manual was published in 1979 and did not cover air brake systems, which have since been introduced.
- A committee was formed in 1998 to revise and update the manual to reflect modern wagon designs, maintenance strategies, and technological upgrades across Indian Railways.
- The updated manual provides comprehensive maintenance instructions for all wagon systems, with a focus on air brake systems. It is intended to serve as a single reference for wagon maintenance.
- Standardized numbering conventions are used for chapters, paragraphs, figures and tables to facilitate future revisions as new stock is introduced.
SUMMER TRAINING PPTOnCoach Care Centre (SICK LINE) Amit Verma
This document discusses the maintenance schedules and processes for different types of coaches in India. It provides the following key details:
1. Coaches are classified as minor, medium or major depending on their capacity of 50-100, 100-250, or above 250 passengers respectively.
2. Maintenance depots are categorized as integral coach factory (ICF), rail coach factory (RCF), link holfmann bushh (LHB), or hybrid depending on the coach design and components.
3. Regular maintenance includes washing after every trip and sick line maintenance on monthly, quarterly, or six month schedules depending on the coach category.
4. The sick line workshop performs repairs and overhauls like
The document provides information about Indian Railways and the North Western Railway zone. It discusses the Mechanical Department which oversees maintenance of rolling stock. It then summarizes the Ajmer Railway Workshop and Carriage Workshop, noting their history and roles in maintaining coaches. The document outlines different types of train maintenance including primary, turnaround, and secondary maintenance. It also describes maintenance schedules for coaches including A-Schedule, B-Schedule and periodic overhauling.
Jhansi Workshop is the biggest Wagon Repair Workshop of Indian Railways. It is
spread in area of 3.4 lakh square meter. The Covered area is 65000 square meter. The
Railway Board Wagon POH target for Jhansi workshop is 610 wagons per month which is
approximately 16 % of the wagon POH done in Indian Railways.
The document is an industrial training report on diesel locomotive technology submitted by Shivam Prajapati. It includes an acknowledgement, contents listing the topics covered in the report such as the introduction of Indian Railways, diesel locomotive shed in Charbagh, diesel electric locomotive components, fuel section, lube oil control section, turbosupercharger, fuel oil pump, bogie, air brake, traction motor, generator, power pack, and failure analysis. It also includes diagrams to illustrate parts of the locomotive like the fuel tank and turbosupercharger.
Summer Training Report on Indian Railways , C& W Workshop, NBQ, AssamDeepjyoti Patowary
This project report is based on Indian Railways Carriage and Wagon Workshop, New Bongaigaon, Assam under North-East Frontier (NFR) Railways. Project is uploaded here only based on educational purpose which will help the students studying engineering and undergoes industrial training. It may have some doubtful information. Readers are asked to re-verify the pieces of information before use.
The Northern Railways is one of the 16 zones and the northernmost zone of the Indian Railways. Its headquarter is New Delhi Railway Station.
Northern Railways is one of nine old zones of Indian Railways and also the biggest in terms of network having 6807 kilometre route.[1] It covers the states of Jammu and Kashmir, Punjab, Haryana, Himachal Pradesh, Uttarakhand and Uttar Pradesh and the Union territories of Delhi and Chandigarh.
This presentation provides an overview of the Carriage and Wagon workshop in Alambagh, India. It discusses the workshop's history and facilities for maintaining various types of passenger coaches. The major sections covered include bogie maintenance, suspension system maintenance, and the various coach types maintained at the workshop, from unreserved coaches to 1AC coaches. An overview is also provided of the key components of bogies, including wheels, springs, frames, and brakes.
This document provides details about Ashutosh Khaitan's six-week industrial training at the Coach Care Centre in Old Delhi railway station from June-July 2013. It includes a training schedule, acknowledgements, abbreviations used, and an introduction to the Coach Care Centre and its role in railway maintenance. The bulk of the document describes procedures for intermediate overhauling of coaches, air brake system maintenance and repair, brake down maintenance, and washing line maintenance.
I had done 1 month summer training on topic " AIR BRAKE SYSTEM USED IN LOCOMOTIVE " from LOCO workshop, LKO....students who are doing so....this file can help them to prepare project file...
This document provides information on different shops in a railway workshop, including the air conditioning shop, power shop, production control organization (PCO) shop, and train lighting shop. In the air conditioning shop sections, it describes the specifications and safety protections of roof mounted package units used for air conditioning trains. The power shop section outlines the substation and protective devices used. The PCO shop discusses the electrical inspections conducted on trains. Finally, the train lighting shop explains the fan and battery sections, including the types of fans and maintenance of lead acid and VRLA batteries.
G 80. inspection and maintenance of centre buffer couplers ( for workshop sta...SrinivasaRao Guduru
The document provides instructions for the inspection, maintenance, and reconditioning of centre buffer couplers. It outlines classification procedures and acceptance requirements for reconditioned parts. Parts can be reconditioned through processes like weld repair and heat treatment, to meet specified hardness levels. Detailed heat treatment procedures are provided for different steel grades. Inspection and maintenance is also described for components like draft gears, clevises and striker castings.
The Liluah Railway Carriage and Wagon Workshop in Howrah, West Bengal overhauls various types of coaches and wagons. It has different shops that perform maintenance like the L shop which handles four types of wagons, the LHB shop which maintains higher speed trains, and the M shop which does overhauls of ICF, BEML, and RCF coaches. The workshop also has facilities like the welding shop, corrosion treatment shop, calibration room, and performs tasks like shot blasting, load testing, and grading/color coding of parts.
The document provides a training report submitted by Anish Malan for his summer training at the Railway Workshop in Jagadhari. It includes an overview of the railway workshop, its organizational structure, production units, quality policies, safety measures followed, classification of rolling stock, important systems and components of rolling stock. It also describes various processes carried out in the wheel shop like boring, axle turning, axle grinding, tapping, wheel press operation, axle journal turning and burnishing, tyre turning. It discusses the zyglo test procedure for roller bearings and ultrasonic test for axles.
The document provides an overview of the Mechanical Workshop at North Eastern Railway in Gorakhpur, Uttar Pradesh. It describes the various shops within the workshop, including the Machine Shop, Shell Shop, Spring Shop, Bogie Shop, and Wheel Shop. The Machine Shop utilizes various types of computer numerical control machines like lathes, mills, drills to machine parts to the required specifications. The workshop oversees the repair and overhaul of railway coaches and aims to modernize its facilities and processes for increased efficiency.
The document provides an overview of Diesel Locomotive Works (DLW) in Varanasi, India, which produces diesel-electric locomotives. DLW was established in 1961 through collaboration with American Locomotive Company and has since produced locomotives using both ALCO and Electro-Motive Division technologies. The document details the various types of locomotives produced at DLW, including their specifications and components.
The document is a practical training report submitted by Pragyadev Singh Rathore during their internship at the Carriage and Wagon Workshop of North Western Railway in Bikaner, India from June 29th to July 30th, 2022. The report provides details of the training received in different sections of the workshop such as periodic overhauling, air brakes, wheel repair, bogie overhaul, and meter gauge operations over the 60 day period to fulfill the requirements for a Bachelor of Technology degree in Mechanical Engineering.
This document provides an industrial training report from the North Eastern Railway Gorakhpur workshop in Uttar Pradesh, India. It includes an introduction to the workshop, acknowledgments, a list of contents, and sections describing various shops within the workshop including the machine shop, painting shop, wheel shop, spring shop, and heat treatment shop. Machines, processes, and typical repairs for components like wheels and springs are outlined in each section.
Harnaut mechanicaL workshop summer training repoRTRohit Bharti
This document provides an industrial training report from Rohit Bharti, a mechanical engineering student, about his 4-week training at the mechanical workshop of the North Eastern Railway in Gorakhpur, India. The report includes sections on various shops in the workshop such as the machine shop, painting shop, wheel shop, spring shop, and jig and fixture shop. It provides details on the operations, processes, and equipment used in each shop. The summary concludes with appreciation expressed for the training and what was learned regarding discipline, determination and devotion.
The document provides background information on the history of Indian Railways and the development of wagons. It then summarizes details about the Wagon Repair Workshop in Kota, including its establishment, facilities, production statistics, and workflow process. The training report aims to provide the student with knowledge of rail coach and wagon manufacturing and repair processes.
The document provides an overview of a seminar report on a practical training taken at the loco workshop of the North Western Railway in Ajmer, India. It discusses the various departments and operations at the workshop, including wheels, machine shop, braking systems, bogie shop, spring shop, diesel section, fuel systems, and scheduled examinations. The report serves to fulfill the requirements for a B.Tech degree in Mechanical Engineering.
The document summarizes the history and activities of the Carriage & Wagon Workshop in New Bongaigaon, Assam. It was established in 1965 to undertake repairs of carriages and wagons for the Northeast Frontier Railway. Over time it expanded its capacity and capabilities to include periodic overhauling of broad gauge coaches and wagons as well as manufacturing wheels for various rolling stock. It currently produces 60 broad gauge coaches, 120 wagons, and 1170 wheels per month. The workshop has grown and modernized over the decades to handle repairs and maintenance for the expanding railway network in northeast India.
Mechanicaal workshop gorakhpur summer training reporthmthimanshu
This document provides an industrial training report from North Eastern Railway Gorakhpur workshop. It includes an acknowledgement, abstract, introduction on Indian Railways, and sections on the machine shop, painting shop, spring shop, heat treatment shop, jigs and fixtures shop, and shell shop. The report describes the various processes, equipment, and purposes of each shop area within the workshop.
Indian Railways - Rail Wheel Factory ReportSameer Shah
The document provides details about an internship project report submitted by Sameer Shah on the rail wheel and axle manufacturing process at Rail Wheel Factory in Yelahanka, India. It includes an abstract, acknowledgements, introduction to Indian Railways and the history of RWF Yelahanka. The report then describes the key production areas at RWF - the wheel shop involving controlled pressure pouring, steel melting using electric arc furnaces, and wheel processing; and the axle shop involving forging and machining.
The document provides information about the Harnaut Workshop located in East Central Railway zone of Indian Railways. Some key details:
- The workshop was established in 2003 to enable self-reliance and improve efficiency as East Central Railway previously had to depend on other zones for carriage repair.
- It has 18 modern repair workshops across 115 acres of land and aims to repair 50 coaches per month.
- The workshop is divided into various sub-workshops including the Sheet Metal Shop, Bogie Repair Shop, Wheel & Axle Shop, and others.
- Machinery present includes a plasma cutting machine, radial drill machine, hydraulic press brakes and shearing machine in the Sheet Metal Shop. The
This industrial training report provides a 3 sentence summary of the document:
The report summarizes Izhar Ansari's 4 week industrial training at the Mechanical Workshop of the North Eastern Railway in Gorakhpur. It describes the various main shops in the workshop, including the machine shop, heat treatment shop, welding shop, wheel shop, paint shop, and spring shop. It also discusses the material handling system and braking system at the workshop.
practical training taken at loco workshop ajmer.
where diesel locomotive engines are came to repair or service.
and wagon are re-painted or repair and service.
there were also assembling a breaking system with respect to bogie,
wheels of bogie are also tested and service in workshop.
Maintenance and Manufacturing of RailwaysSwapnil Pawar
The document provides details about an internship training project conducted by three students at the Central Railway Locomotive Workshop in Parel, Mumbai. It includes an introduction to the workshop, certificates of completion for the students, an acknowledgment, and an index of topics covered in the internship report such as air brakes, toilets, corrosion, welding, and locomotive systems.
diesel locomotive works training report by somesh dwivedisomesh dwivedi
4week summer training report on D.L.W. Varanasi by Somesh Dwivedi.
on the topics 1.-Heavy Weld Shop(HWS)
2.- Heavy Machine Shop(HMS)
3. Light Machine Shop(LMS)
4. Truck Machine Shop(TMS)
The document is a training report submitted by Rajat Kumawat to Rajasthan Technical University in partial fulfillment of the requirements for a Bachelor of Technology degree in Mechanical Engineering. The report details Rajat's industrial training at the North Western Railway in Jaipur, Rajasthan, India under the guidance of Mr. Naveen Meena, Coaching Depot Officer. It includes sections on the organization structure of Indian Railways, an introduction to North Western Railway and its divisions, details of various parts of LHB coaches including wheels, axles, bogies, braking systems, toilets and maintenance practices.
This document is an industrial training report submitted by Himanshu S. Singh to Ramendra Kr. Visen on his training at the Diesel Locomotive Workshop in Varanasi. The report provides background on Indian Railways and the history and operations of the Diesel Locomotive Workshop, including its establishment, annual production capacity, manufacturing processes, and departments.
This document is an industrial training report submitted by Shivendra Singh about diesel locomotive technology at the Northern Railway Locomotive Workshop in Gonda. It includes:
1. An acknowledgment thanking those who helped with the project.
2. An introduction to the diesel locomotive shed in Gonda and its functions in maintaining locomotives.
3. A section on the components and workings of a diesel-electric locomotive, including the turbocharger and bogie.
There is briefly description about different workshops, thus demonstrating the practical aspects of the work. This report is merely the manifestation of all the work being done at Pakistan Railways, the real knowledge lies in doing the Internship yourself.
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Time Division Multiplexing (TDM) is a method of transmitting multiple signals over a single communication channel by dividing the signal into many segments, each having a very short duration of time. These time slots are then allocated to different data streams, allowing multiple signals to share the same transmission medium efficiently. TDM is widely used in telecommunications and data communication systems.
### How TDM Works
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1. 1
A
SUMMER TRAINING REPORT
ON
CARRIAGE WORKSHOP NORTH WESTERN RAILWAY
JODHPUR
Submitted in the partial fulfillment for the
Award of degree of
Bachelor of Technology
IN
MECHANICAL ENGINEERING
SESSION – 2014-2018
Submitted By:
Sachin Deora
B.Tech. (Final Year)
Mechanical Engineering
V.I.E.T. Jodhpur
Submitted To:
Prof. Shailendra Bohra
HOD (Mechanical Dept.)
V.I.E.T. Jodhpur
VYAS INSTITUTE OF ENGINEERING & TECHNOLOGY
JODHPUR (RAJASTHAN)
2. 2
Carriage workshop – jodhpur
NORTH WESTERN RAILWAY
SUMMER TRAINING REPORT
27/5/17 – 15/7/17
Submitted By:
Sachin Deora
B.Tech. (Final Year)
Mechanical Engineering
V.I.E.T. Jodhpur
Submitted To:
Mr. N.S. Pundir
Incharge B.T.C.
North Western Railway
Workshop, Jodhpur
3. 3
ACKNOWLEDGEMENT
Engineering is the field where only theoretical knowledge cannot satisfy
Engineer’s need & on that basis an Engineer cannot carry on efficiently so it is
important for an Engineer to gain Practical knowledge. So the knowledge of other
fields like Accounts, Personnel etc. are necessary. Considering these points
Rajasthan Technical University makes the Training Module for B.Tech persuing
students for 50 Days. This includes both Theoretical & Practical gains.
I am very thankful to Training and Placement officer VIET – Mr.
Rajkumar Vyas for providing me opportunity of the training. I am also thankful to
Sh. N.S. Pundir(Chief Incharge), Sh. M.S. Solanki(Sr. Instructor) Sh. R.K. Jain(Sr.
Instructor), Sh. Hemant Singh(Sr. Instructor), Sh. Rajesh Purohit(Sr. Instructor),
B.T.C. and all the SSE, Jr. Engineer and other workers In- NWR Workshop, JU for
their kind support.
SACHIN DEORA
B.Tech. (Final Year)
Mechanical Engineering
V.I.E.T. JODHPUR
4. 4
INDEX
S.No. Contents Page No.
1. INTRODUCTION 4
2. SALIENT FEATURE OF INDIAN RAILWAY 6
3. OTHER INTERESTING FACTS OF INDIAN RAILWAY 7
4. FULL TRAINING SCHEDULE - (50 DAYS) BY RAILWAY BOARD 8
5. HIERARCY IN JODHPUR WORKSHOP 9
6. BASIC TRAINING CENTER-JODHPUR 10
7. NETWORK FOR POH 11
8. FITTING SHOP 13
9. WELDING SHOP 15
10. C.B.C.R. SHOP 17
11. LIFTING SHOP 18
12. TRIMMING SHOP 21
13. COROSSION SHOP 22
14. PAINT SHOP 25
15. BRAKE GEAR SHOP 27
16. WATER TANK SHOP 31
17. MACHINE SHOP 33
18. FABRICATION SHOP 34
19. MILL WRIGHT SHOP 35
20. ROLLER BEARING SHOP 37
21. WHEEL SHOP 41
22. SPRING, BUFFER, AND HEAT TREATMENT SHOP 43
5. 5
INTRODUCTION
Workshop is located near main Railway station of Jodhpur. This workshop is well
established and running successfully as a complete organization.
In 1969, to increase administrative efficiency, the post of
“Works Manager” was upgraded to Deputy Chief Mechanical Engineer.
Now a days, this workshop has not only stopped importing
valuable and costly components but also started the production of some essential
and sophisticate components.
Along with this, the basic role of Jodhpur workshop is: -
1. Periodic over hauling of the Railway coach and bogies at the level.
2. Manufacture and repairing of components used in Diesel engine for
Diesel shed.
3. Maintenance and repairing of all the machines, which are installed in
Jodhpur Railway station.
4. Now a days, it is also engaged in production of some components,
which needs to be replaced in Railway coaches and bogies.
6. 6
JODHPUR WORKSHOP
Total Area 28.5 Acre (115339 Sq. Meter)
Total Covered Area 55817 Sq. Meter
Rail Track within Workshop 5400 Meter
Road within Workshop 1758 Meter
Power requirement 850 KVA
Availability of Standby
Power 920 KVA
No. of M&P 363 Nos.
Present outturn 74 BG Coaches / Per Month
Water Pumping Capacity 350 KL/Hr.
Water Storage Capacity 3337 KL
Overhead Tank Capacity 250 KL
Health unit 01 Nos.
Address Carriage Workshop,
North Western Railway,
Jodhpur 342001.
Telecommunications 0291-2432140
Fax 0291-2610496
7. 7
Salient Features of Indian Railways
The first railway on Indian sub-continent ran over a stretch of 21 miles from
Bombay to Thane. The formal inauguration ceremony was performed on
16th April 1853.
Thus the first section of the East Indian Railway was opened to public traffic,
inaugurating the beginning of railway transport on the Eastern side of the
subcontinent. These were the small’s beginnings which is due course
developed into a network of railway lines all over the country. By 1880 the
Indian Railway system had a route mileage of about 9000 miles.
INDIAN RAILWAYS, the premier transport organization of the country is the
largest rail network in Asia and the world’s second largest under one
management.
Track and gauge
Broad Gauge
(1676 mm)
Meter Gauge
(1000 mm)
Narrow Gauge
(762/610 mm)
TOTAL
Track Kilometres 108,500 km 5,000 km - 115,000 km
Route Kilometres 59,400 km 4,100 km 1,500 km 67,312 km
NOTE: About 27,999 km (17,398 mi) or 42% of the route-kilometre was electrified, as of
31 March 2016
8. 8
Other Interesting facts of Indian Railways:
IR's rolling stock comprises over 245,267 Freight Wagons, 66,392 Passenger
Coaches and 10,499 Locomotives (43 steam, 5,633 diesel and 4,823 electric
locomotives).
The trains have a 5 digit numbering system and runs 12,617 passenger trains
and 7,421 freight trains daily.
RAILWAY ZONES
S.NO
.
NAME HEAD
QUARTERS
DIVISIONS
1. Central Railway Mumbai Mumbai, Bhusawal,
Pune, Solapur, Nagpur
2. East Central Railway Hajipur Danapur,Dhanbad,Mughalsarai, Samastipur, Sonpur
3. East Coast Railway Bhubanes
war
Khurda Road, Sambalpur and Waltair
(Visakhapatnam)
4. Eastern Railway Kolkata Howrah, Sealdah,
Asansol, Malda
5. North Central Railway Allahabad Allahabad, Agra,
Jhansi
6. North Eastern Railway Gorakhpur Izzatnagar, Lucknow,
Varanasi
7. North Western
Railway
Jaipur Jaipur, Ajmer,
Bikaner, Jodhpur
8. North East Frontier
Railway
Guwahati Alipurduar, Katihar, Rangia, Lumding, tinsukia
9. Northern Railway Delhi Delhi, Ambala,
Firozpur, Lucknow, Moradabad
10. South Central Railway Secundera
bad
Vijayawada,Hyderabad,Guntakal,Guntur,Nanded,Sec
underabad
11. South East Central
Railway
Bilaspur Bilaspur, Raipur,
Nagpur
12. South Eastern Railway Kolkata Adra, Chakradharpur,
Kharagpur, Ranchi
13. South Western
Railway
Hubli Hubli, Bangalore,
Mysore
14. Southern Railway Chennai Chennai, Trichy,Madurai,Salem
Palakkad, Thiruvananthapuram
15. West Central Railway Jabalpur Jabalpur, Bhopal, Kota
16. Western Railway Mumbai BCT,Ratlam,Ahmedabad,Rajkot,Bhavnagar,Vadodara
17. Metro Railway,
Kolkata
Kolkata
13. 13
Shop Details in NWR Workshop, Jodhpur
S.NO. SHOP DETAILS WORKING
1 Water Tank Repair of Water Tank & Plumbing work
2 Machine Manufacturing & Repair of various items of POH of
Coaches & other items as per work order
3 Fabrication Battery Box repair & other Fabrication work
4 Mill Wright Mechanical maintenance of Machinery & Plants,
Transportation of Materials
5 Roller Bearing POH work of Roller Bearing of Wheels for Coaches &
Diesel Locomotives
6 Wheel POH work of Wheels for Coaches & Diesel Locomotives
7 Buffer Spring & Heat Cleaning, Repair, Inspection & Testing of Spring, Buffer &
Treatment Draw Gear items, Heat Treatment of various items
8 Fitting Repair Strip & Fit of Doors, Window Seats, Berths & other
Miscellaneous work
9 Welding Welding work of all items during POH of POH work
10 Carriage Building & Internal Furnishing work of Coaches such as Sun mica,
Carriage Repair PVC Flooring & Carpentry work & Traverser Shunting
11 Lifting Lifting & Lowering of Coaches, Repair of Bogie items,
Dismantle & assemble of Bogie and Buffer, Striping and
Fitting of Battery Box & Draw Gear
12 Trimming Berths Cushioning & Repair work, Sewing work of Coach
Curtains
13 Corrosion Repair Corrosion Repair work of Coaches & Battery Box Repair
14 Paint Painting work of Coaches
15 Brake Gear Maintenance of Brake Gear System of Coaches
16 Tool Room Stripping, Repairing, Testing & Fitting of Shock Absorber,
Gauge manufacturing & Calibration work
17 Laboratory Testing of various items such as Paint, Grease etc., Non
Destructive Test such as DPT, Magna Flux & UST etc.
18 Progress Checking of Stock & Non Stock items, Corresponding for
Material to Head Quarter, Store & others
19 Yard & Transport Coach Shunting work in Workshop, Sweeping & Cleaning
work of Workshop
20 Basic Training Centre Training work of various apprentices & artisan Staff
21 Planning Planning of Work Order items, Printing of Route Cards, Job
Cards & GA Cards etc.
14. 14
FITTING SHOP
Work done in Fitting shop:
Ring below seat(For securing luggage).
Foot step repair.
Cover for condenser motor.
Dirt collector cover with clip.
Iron box for emergency window box.
Upper birth handle.
Lavatory commode chute.
Alarm chain cover.
Window safety latch.
Seat repair and welding work.
Commode ring.
Door handle.
Door locking plate.
Dust bin.
Water tube for dog box.
Lavatory pan repair.
Seat bracket for lower birth.
Dog box door.
Door locking.
Door pivot assembly.
Hand rest bracket.
Clip for rolling shutter.
Attendant seat.
Bracket for luggage safety.
Plate for door pivot support.
Lavatory window frame.
Upper berth hook plate.
SLR hinges male & female.
Side door packing washer.
AC Chair car bake seat spring.
15. 15
PU ladder for upper berth.
Sliding door bottom guide.
Back rest bracket.
Emergency open able window.
Manufacturing of reflector.
Door handle lock spring.
Tail lamp bracket for SLR coach.
Conversion of lavatory window bar from horizontal to vertical position for
anti-climbing purpose.
16. 16
WELDING SHOP
Definition:
“Process of joining two similar or dissimilar metals by heat or by pressure/without
pressure or by both with or without a filler metal to achieve a defect less joint
having the physical properties similar to that of parent metal”.
• Commonly welded base metals:-
• Ferrous-[WI, CI, C-steel(low,med,high),alloy steel,SS]
• Non-ferrous-(Al, Cu ,Mg, Ni, Zn & their alloys)
• Plastic, ceramics, composites, etc. can be welded but not by the same
process
• Weld material should have good fatigue properties in addition to
strength & toughness.
Dissimilar metal means:-
Those that are chemically different (steel, Cu, Al, etc.).
Those that aremetallurgically different (MS, SS, etc.).
*Dissimilar metal imparts galvanic cell corrosion.
WELDING PROCESSES USED IN RAILWAYS:
• SMAW
• MMAW
• SAW
• MIG/MAG
• TIG/GTAG
Welding Defects &It’s Evaluation-
Performance of welded component in service depends on:
The presence or absence of defects in weld joints.
Defects impair the mechanical properties of weld joints
Definition of welding defects:-
“Defects introduced during welding beyond the acceptance limit that can
cause a weld to fail”.
17. 17
Classification of welding defects:
Crack- includes all types of cracks such as crater cracks, hot cracks, cold
cracks
Cavity- includes blow holes, porosities, shrinkage, pipes
Incomplete fusion & penetration- includes lack of fusion, lack of
penetration
Solid inclusion- includes slag, metal oxides, tungsten, wagon track
Imperfect shape -under cut, under fill, overlap, excessive penetration,
improper bead shape, etc
Miscellaneous defects –includes arc strike, excessive spatter, rough surface,
uneven ripples.
18. 18
C.B.C.R. SHOP
Work carried out by CBCR shop:
After receiving coach for POH, first of all deficiencies are noted down.
CBCR inspection dept. note down & mark the work to be done by CBCR
shop. Similarly trimming shop and corrosion shop note down the work.
Carpenter opens the seats marked by inspection team and the same is sent to
trimming shop. Moulding on seats are also opened by CBCR team.
Sunmica board, panel board etc. are being removed by CBCR for corrosion
work to be carried out by corrosion shop.
PVC is also removed by CBCR in compartment and lavatory for corrosion
repair.
Sunmica work, wooden panelling work is performed by CBCR
New sunmica, pvc floor, panel work is being done which were removed for
corrosion work.
Arch panel being opened for water tank work is also being done by this
shop.
Interior fitting and passenger amenity items are fitted by this shop.
Seats and berths repaired by trimming shop are re-fitted by CBCR SHOP.
19. 19
LIFTING SHOP
BOGIE
Main Components of Bogie
1. Center pivot, bolster, and side bearer
2. Bogie frame, axle guide
3. Roller bearings
4. Suspensions
5. Damping arrangement and bump stops
6. Traction component
7. Wheel and axle
Bogie Frame with Axle Guides
1. 2 sole plates (side frames).
2. 2 headstock at either ends
3. 2 transoms at centre.
4. 4 longitudinal.
8 axle guides welded to the side frame with close dimensional accuracy
20. 20
Function of Axle Guide:
1. Guides the axle laterally as well as longitudinally.
2. Transmits tractive & braking force between bogie frame & axle box.
3. Acts as a single acting hydraulic vertical shock absorber for primary
spring.
Anchor Link
1. Fitted with silent block.
2. Transmits the tractive and braking forces.
3. Can swivel universally
1. To permit the bolster to rise & fall and to sway side wards.
Centre Pivot
1. Facilitates body-bogie joint.
2. Transmits the tractive & braking forces.
3. Rubber silent block
4. Tends to centralize the bogie.
21. 21
Maintenance of Bogie:
Final adjustment
lowering of coach
Load testing and adjustment
bogie assembly
Repair of components
Attention to component
component cleaning
Bogie dismantling
Bogie cleaning
Coach lifting
22. 22
TRIMMING SHOP
Process chart for repair of seat and berth:
1
• Reciept of seats from CR section.
2
• visual insoection for new/repair.
3
• washing with soap solution.
4
• strip off nack ply seats and berths.
5
• remove rexine, rubberised coir from frame.
6
• repair of wooden/iron frame.
7
• marking and cutting of new sizes of rexine.
8
• stiching rexine as per size.
9
• fitting repaired rubber foam/rubberized on frame coir.
10
• fitting of rexine/back ply.
11
• painting of back ply of berths.
12
• dispatch to CR section.
23. 23
CORROSION SHOP
1. Corrosion is the slow but spontaneous deterioration of materials by
chemical or electro-chemical reaction with its environment.
2. Formation of a layer of reddish brown scale on the surface of iron
(rusting of iron).
3. Formation of green layer on the surface of copper when exposed to moist air
and CO2.
Corrosion rate
1. Highly reactive metals (Na, K, Ca) corrode rapidly even at room temp.
2. Noble metals are not corroded even at high temp
3. Higher the temp, greater is the corrosion
4. In absence of dissolved O2, rate of corrosion at room temp is negligible both
for iron & steel.
Cause of corrosion: Coaches
1. Water seepage through flooring to the top of the tough floor
2. Leakage of water through lavatory flooring.
3. Habits of flushing the flooring with the water jet for cleaning.
4. Defective water pipe fittings
5. Blockage of drain water by accumulated dust on top of tough floor.
6. Surface preparation not prepared properly for carrying out welding activity.
7. Recommended material not being used due to non-availability.
8. Surface preparation not prepared properly before starting of paint.
Prone Area in Passenger Coach
1. Tough Floor: Adjacent to lavatory, doorways & kitchen area of pantry car.
2. Side wall bottom: Below lavatory & between body side pillar.
3. Sole Bar: In the lavatory area & doorways.
4. Body Pillar: Bottom portion
5. Cross Bearers: Joint between sole bar & cross bearers.
6. Body Side Door: Bottom of door
7. Roof: Ventilator & its area.
8. Battery Boxes: Corrosion due to acid action.
24. 24
Parts of the Shell requires Corrosion Repair
1. Head Stock
2. Sole Bar
3. Side Wall members
4. Tough Floor
5. Roof
6. Partion wall, Seat pillar/Mounting plate
7. Body bolster, Centre pivot
8. Floor channel
Procedure of Maintenance of Under frame
Thoroughly inspected for locating cracked/bent/corroded members
Corrosion checked
o By flaking of paint/flaking of metal, pitting & scale formation.
Sole bar & trough floor
o By tapping with a spiked hammer.
Replacement needs after reducing 20% of its thickness.
Corrosion Repair to Under frame Members
Coach body kept on trestles
Use corrosion resistant steel sheet.
Electrodes of approved brands
Paints
Red oxide zinc chromate primer
Bituminous anti-corrosive solution
Method of repair
Where corrosion just started
o Paint & rust thoroughly clean to reach the bare metal & give two coats
of primer & two coats of paint.
Where heavy corrosion
o Replace the item
25. 25
Corrosion prevention method
1. Proper designing
2. Proper selection of materials for the environment concerned
3. Cathodic protection
4. Modification of the environment
5. Corrosion inhibitors
26. 26
PAINT SHOP
Types of Paint
Alkyd paint
PU paint
Epoxy paint
Painting Procedure
Surface preparation.
Priming of surface.
Putty, filler, etc.
Under coats
Top coats
Surface Preparation
Blasting process:
1. Sand blasting
2. Shot blasting
3. Grit blasting
4. Wet blasting
5. Hydro blasting
Primer
1. Acts as barrier
2. Makes the surface more paintable
3. Provides corrosion protection
4. Better adhesion for coatings
Putty
1. Dough like stiff paste applied by knife.
2. Used to fill dents & to level undulations.
3. Excessive coating thickness (275 microns max) to be avoided to
minimize flaking
27. 27
Filler
1.
Used for filling up of pin holes, scratches, etc for getting uniform
surfaces after the application of putty.
Undercoat
1. Intermediate coating between primed/putty applied surface & top coat.
2. Purpose:-
a. To improve adhesion between primer/ Putty & top coats.
b. To protect the primer provides a base for the finish coat for giving
aesthetic look
Top Coat
1) Normally one or two coats for required
2) Purpose:
3) Provides aesthetics of color and gloss
4) Protects against environment
5) Protects from:
a. Destructive UV light
b. Ingress of air & moisture
c. Chemicals and corrosive fumes.
Paint Schedule in POH
1. 1st
Day-Remove old painting.
2. 2nd
Day-One coat primer.
3. 3rd
Day-One coat brush filler.
4. 4th
Day-2nd
coat filler with putty
5. 5th
Day-Rub down with SiC paper
6. 6th
Day-One coat of undercoat
7. 7th
Day-Flat with SiC paper & apply one coat of enamel finish
8. 8th
Day-Flat with SiC paper gr-400 & 2nd
coat of synthetic enamel finish
9. 9th
Day-Letters.
28. 28
BRAKE GEAR SHOP
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 reservoir and the brake pipe is
connected to the brake cylinder through the distributor valve.
Brake application takes place by dropping the pressure in the brake pipe
Principle of operation of Twin pipe graduated release air brake system:
SCHEMATIC LAYOUT OF TWIN PIPE GRADUATED RELEASE AIR BRAKE SYSTEM
29. 29
Charging the brake system:
Brake pipe throughout the length of train is charged with compressed air at 5
Kg/cm2
.
Feed pipe throughout the length of train is charged with compressed air at 6
Kg/cm2
.
Control reservoir is charged to 5 Kg/cm2
.
Auxiliary reservoir is charged to 6 Kg/cm2
.
Brake application stage:
For brake application the brake pipe pressure is dropped by venting air from
the driver’s brake valve.
o Subsequently the following actions take place
o The control reservoir is disconnected from the brake pipe.
o The distributor valve connects the auxiliary reservoir to the brake
cylinder and the brake cylinder piston is pushed outwards for
application of brakes.
o The auxiliary reservoir is however continuously charged from feed
pipe at 6 Kg/cm2
Brake release stage:
Brakes are released by recharging brake pipe to 5 Kg/cm2
pressure through
the driver‟s brake valve.
The distributor valve isolates the brake cylinder from the auxiliary
reservoirs.
The brake cylinder pressure is vented to atmosphere through DV and
the Brake cylinder piston moves inwards.
AIR BRAKE SUB ASSEMBLIES
The various Air Brake sub-assemblies and components are:
Common pipe bracket
Intermediate piece
Brake pipe and feed pipe
Brake pipe coupling
Cut-off angle cock
Brake cylinder
Dirt collector
Auxiliary reservoir
Slack adjuster
Distributor valve
30. 30
isolating cock
PEASD
PEAV
Check valve
DISTRIBUTOR VALVE
Distributor valve is the most important functional component of the air
brake system and is also sometimes referred to as the heart of the air brake
system
The distributor valve senses drop and rise in brake pipe pressure for brake
application and release respectively.
It is connected to the brake pipe through branch pipe.
Various other components connected to the distributor valve are auxiliary
reservoir, brake cylinders and control reservoir.
Periodicity of Overhauling:
The overhauling of the distributor valve is carried out once in five years or
on completion of 8 lakh km whichever is earlier or if there is some specific
trouble.
DV tests:
Charging time of auxiliary reservoir and control reservoir
Pressure tightness test
Full service application and release test.
Overcharge protection test
CR over charge reduction test
Emergency application test
Sensitivity test
Quick service test
Insensitivity test
Re-feeding test
Graduated application test
Graduated release test
Quick release test
CR check valve reset test
31. 31
C3W DISTRIBUTOR VALVE
The C3W distributor valve consists of:
1) Main body
2) Quick service valve
3) Main valve
4) Limiting device
5) Double release valve
6) Auxiliary reservoir check valve
7) Cut off valve
8) Application choke
9) Release choke
OPERATION OF C3W DISTRIBUTOR VALVE
For effective functioning of air brake system, the distributor valve has to
operate effectively during
1) Charging stage
2) Application stage
3) Release stage
32. 32
WATER TANK
Repair of water tank and plumbing work of coaches. Capacity of water tank in
ICF= 455L. water tank is repaired in every alternate POH and if on visual
inspection found defective it is removed on every POH.
Types of water tank:
1. For non-ac coach: overhead water tank are used and they are of two types.
Two piece
Three piece
Presently two piece water tank are being used. It is made of aluminum alloy
having thickness 5mm and weight approx. 60 kg.
2. For AC coach: under slung water tank are used in AC coaches.
It’s made of stainless steel (SS). In AC coach, for lifting water mono block
pump are used. Those is one horizontal assistance tank in lavatory of
capacity 40L.
Major material used in water tank shop:
Tee, elbow, socket, nipple, reducer socket, flush cock, lift cock, fish toil, ½”
G.A pipe, ½” PVC pipe, 1” GA pipe, 1”PVC pipe, PVC washer etc. To make
thread on pipe threading M/C is being installed along with pipe cutting M/C.
MATERIAL COMPOSITION OF WATER TANK USED IN IR:
Aluminium: GR 3100 as per IS-73786, Tensile – 130 to 180 mpa.
1. CU% -0.1max
2. Mg% -0.1max
3. Si% -0.6max
4. Fe% -0.7max
5. Mn% -0.8to0.5max
6. Zn%,Ti%, Cr% -0.2max
33. 33
Common defect in water tank are bottom of welding joint crack and leakage in any
pipe fitting.
Repairing Procedure
1. Removing of scale
First of all, water tank are dismantled from coaches and then scale
removed by light hammering on water tank, which is formed by applying hard
water in the water tank.
2. Visual Inspection
After first stage, water tank is inspected visually and marking the fault
such as pitting, failure in welding.
3. Welding of Pitted Part
After marking of fault in water tank, welding is done by using of gas
welding with filler material Al rod and flux as a oxidising material.
4. Testing
After this process water tank is filled with water completly and tested
under a pressure of 0.34 Kg/sq.cm..
34. 34
MACHINE SHOP
Major work done under machine shop are for following parts-
1. Anchor link bracket.
2. Bracket for anchor link on bogie frame.
3. Brake head.
4. Drilling in battery box.
5. Jack bolt,nut& guide bush for welding of head stock fixture.
6. Rail bus- shock absorber nut & bolt.
7. Other work as per drawing.
Material of cutting tool used in m/c shop-
Carbon steel- carbon 0.8 to1.5%. temperature should be below 200°c during work.
HSS- 3 time superior than carbon steel. Temperature during work should be below
900°c.
Cutting fluid uses-
1. To cool tool.
2. To cool job.
3. To reduce friction.
4. To increase surface finish.
5. To protect job & machine parts for corrosion.
6. To reduce chips.
7. To remove chips from tool & job.
Machines used in machine shop-
1. Capstan lathe
2. Centre lathe
3. Horizontal boring
4. Milling Machine
5. Power hacksaw
6. Pedestal grinder
7. Pipe thread cutting
8. Universal Radial drill
9. Shaper
10. Slotter
11. Turret lathe
35. 35
FABRICATION SHOP
Components repaired under fabrication shop-
Battery box for AC coach.
Battery box for Non-AC coach.
Air hose coupling support bracket.
Centre stiffener for head stock.
Side bearer cover plate assembly.
Body pillar.
Side bearer on body bolster.
Arrangement for bracket.
Hook for suspension.
Modified equalising stay.
UIC vestibule foot plate.
Bogie bolster arrangement.
Foot step arrangement.
UIC vestibule frame.
Manufacturing bogie bolster housing for side.
U type window frame assembly.
Window channel with assembly.
D type striking plate.
Seat pillar.
Door-handle plate.
Condenser safety grill.
36. 36
MILL WRIGHT SHOP
Mechanical maintenance of machine plant, transportation of material:
The shop is divided into basically three sections.
1. EOT- electric hoist, traverser, machine of fabrication shop, machine shop
etc.
2. MAINTENANCE OF M/C- wheel shop, roller bearing shop, m/c shop,
fitting shop etc.
3. TRANSPORT- all vehicles and compressors.
Other work performed by mill wright are repair of weight m/c and ticket
m/c etc.
General work in shop:
1. maintenance of m/c
2. installation and errection
3. machine tool repair
4. preventive maintenance.
Preventive maintenance system-
G I R I R I M I R I R I M I R I R I G
G- general overhaul
R- routine repair
M- medium repair
I- inspection.
I=9, M=2, R=6.
37. 37
Advantages of preventive maintenance system:
1. Reduce breakdown.
2. Reduce overtime & lesser odd time repair.
3. Greater safety for workers.
4. Fewer large scale & repetitive repair.
5. Law maintenance & repair cost.
6. Low consumption of spare parts.
7. Increased life, better product quality, at low cost.
8. Better industrial relation because workers don’t face lay off & loss of
incentive scheme.
38. 38
ROLLER BEARING SHOP
Construction feature of Roller Bearings
Spherical roller bearing consist of an outer ring having a continuous
spherical raceway within which operate, two rows of barrel shaped rollers,
which in turn are guided by an inner ring with two raceways separated by a
Centre rib. The spherical roller bearings have self-aligning properties and
therefore can automatically adjust to any deviation in the Centre line of the
axle.
Spherical roller bearings have a large capacity for radial loads, axle loads in
either direction, and complex loads. They are suited for the applications such
as railway rolling stocks where vibrations and shock loads are encountered.
Roller Bearings are named according to the shape of rollers. Roller Bearings
with spherical rollers are called as Spherical Roller Bearings.
Spherical Roller bearing no. 22326/C3 with 130 mm parallel bore on the
inner ring are being used on ICF type coaches. They are directly shrunk fit
on the axle journals.
These roller bearings need to be inspected periodically at a pre-defined
schedule in the workshop in a Roller Bearing Maintenance Shop well
equipped with all the facilities and proper lay out.
39. 39
Periodicity of Inspection of Roller Bearing
All roller bearings should be cleaned, inspected and filled with fresh grease
at every POH.
All bearings should be dismounted every alternate POH or 2 lakh km
whichever is earlier in the workshop for renewal of felt sealing ring and
overhaul of the roller bearings.
Sr. Nature of Work Equipment/Facility required
1 Cleaning of Roller Bearing
Automatic roller bearing cleaning
equipment with 3
stage cleaning of pre-wash, wash and
water rinsing.
2 Cleaning of Axle Boxes
Axle box cleaning plant with Bosch tank
and spray
jet cleaning in a close chamber
3 Axle Box extraction Axle Box extractor
4
Dismounting of Spherical Roller
Bearings - Hydraulic dismounting
taper bore Equipment – Withdrawal Nut
5
Dismounting of Spherical Roller
Bearings - Hydraulic
straight bore Dismounting equipment
6 Mounting of Roller Bearings
Induction heater with de-magnetising
device
7 Securing of end locking bolts Torque wrench and torque wrench tester
8
Visual inspection of dismounted
roller Magnifying glass with light
bearings
9
Measuring/checking of radial
clearance
Long feeler gauge set with number of
leaves with
different thickness
10
Measurement of journal/ shoulder
diameter Outside micrometers
11 Inspection of axle end tapped holes Thread plug gauges for different sizes
of tapped holes
12 Inspection of locking bolts Thread ring gauges for different sizes of
Locking bolts
13 Exact quantity of grease to be filled Volumetric containers with different
Sizes for different quantity of grease
14
Identification of bearings, inspection
details Engraving / Etching machine
40. 40
Checking bearing radial clearance in
mounted condition
Bearing make Radial clearance in mm
SKF 0.105 to 0.296 mm
FAG/NORMA 0.080 to 0.185 mm
NEI/NBC 0.080 to 0.190 mm
Lubrication
The quantity of grease filled per axle box
SKF make
bearing 2.00 kg
Other make
bearings 1.75 kg
Only lithium base grease of approved brands should be used.
Mounting of spherical roller bearings and axle box components
Mounting of Labyrinth Ring (Collar):
The labyrinth ring has an interference fit on the journal, and therefore requires
heating for shrink fitting. Heat the labyrinth ring up to a temperature of 1000
C
max. Recommended grades of oil for heating are:
Yantrol 150 (HPCL)
Servoline 150 (IOC)
Enklo 68 (HPCL)
Servosystem 68 (IOC)
Mounting of Rear cover, Felt Seal & O-Ring (Collar):
Wipe and clean the rear cover and insert 4 nos. bolts. Fill "V" grooves of rear cover
with grease and fit rubber O-ring in its position. Now soak the felt seal in warm
41. 41
cylinder oil (IS: 1589 type 1 grade 3), heated to 40o
C to 50o
C for about 30
minutes. Smear the felt seal by hand with same grease as used in axle box and fit
into the groove at rear cover. Always use new felt seal of specified quality.
Mounting of Spherical Roller Bearing:
direct mounted spherical roller bearing for passenger coach have interference fit
with axle journal, therefore it requires heating and shrink fitting. Heating of
bearings can be done either by using an oil bath or induction heater. Usually,
temperature range of 100 to 1200
C give sufficient expansion for easy sliding of
bearing over journal. However, while heating by either of these methods, do ensure
that temperature of bearing does not exceed 120o
C.
The Induction heater should be equipped with:
Temperature and cycle time controllers Auto demagnetizer
Temperature and cycle time indicator Auto alarm to indicate completion of
cycle.
Bearing should be rejected for following defects:
Pitted or flaked roller tracks and rollers.
Cracked or deformed or badly worn out cage.
Cracked inner or outer ring.
Scored or damaged outer surface of the outer ring.
Scoring of roller tracks or roller.
Rust/corrosion damage or excessive fretting corrosion.
Brinelling or false brinelling.
Rings exhibiting deep straw or blue or purple colour indicating heat effect.
Excessive or less radial clearance.
42. 42
WHEEL SHOP
WHEEL AND AXLE:
The movement of rolling stock on the track is possible only with the help of
wheels.
Components of a wheel set
A wheel set is an assembly mainly of two components:
Wheel discs(solid) on both sides of the axle.
An axle to hold these wheel discs in position.
Maintenance Procedure in the Workshop:
Pre-inspection of wheels in the workshop
During pre-inspection of incoming wheels, the wheel-set is inspected for
assessing the condition of the components. Following measurements are
carried out on all the wheels, received in shop for repairs.
a) Measurement of a wheel gauge(distance between two wheels
flanges on the same axle)
The distance between two wheel flanges on the same axle should be 1600
mm+ 2/-1 mm.This measurement should be taken at three locations apart
with the help of an adjustable pi gauge. If wheel gauge is not within
permissible limits, then the wheel disc (s) have to be pressed off and then
pressed on.
b) Measurement of Wheel Diameter (Tread Diameter)/Wheel Flanges
The wheel diameter is measured with the help of a trammel gauge with a
least count of 0.5 mm. on both sides. However, a gauge with a least count
of 0.1 mm. is recommended as the measurement of a diameter would be
more accurate with this gauge.The difference in tread diameter of the two
wheels on the same axle should not exceed 0.5 mm after tyre turning. There
is no 'In service' limit for this variation and rejection shall be decided by
tyre defect gauge.
During last shop issue the wheel is to be turned to RDSO SK-91146. The
profile is to be turned 1 mm above the condemning limit groove. The
maximum diameter and last shop issue size for ICF type wheels is given
below.
43. 43
Inspection of axle
Axle journals should be thoroughly cleaned for inspection to detect flaws,
pitting, ovality, taper, ridges etc. Each axle should be ultrasonically tested
for detecting internal flaws and defects as per the code of procedure issued
by RDSO). Axles found flawed, pitted or with under size journals should be
replaced.
On ICF axle journal
A taper should not exceed 0.015 / 0.010 mm.
Out of roundness (ovality) must not exceed 0.015 / 0.020 mm.
Type of New Min. Shop
wheel issue
ICF solid 915 836
c) Inspection of wheel disc
The wheel should be inspected for rejectable defects in accordance with
RDSO‟s instructions
• Inspection of Wheel Flanges
The flanges on both sides of a wheel set are checked with the help of a
profile gauge to measure the height and thickness of flanges. Accurate
measurement of flange height and flange thickness is not possible with
the profile gauge. It is, therefore, recommended to use a wheel profile
gauge with which accurate measurement of flange height and flange
thickness to the extent of 0.1 mm can be made.After recording the
diameters of wheels and wheel flange measurements, the wheel set is
nominated for necessary repairs.
44. 44
SPRING,BUFFER & HEAT TREATMENT
This shop deals with the maintenance ,testing and heat treatment of various
components of bogie like soring (both primary & secondary),buffer assembly
complete , screw coupling, BSS hanger, Draw gear.
Maintenance procedure of springs-
1. Caustic soda wash tank.
2. Cleaning – shot peening.
3. Visual inspection.
4. Electro magna crack testing.
5. Anticorrosion and black japan paint.
6. Year, manufacturing number.
7. Load testing.
8. Grouping.
9. Colour coding.
10.Despatch.
SHORT PEENING M/C-
Name - twin rotary table shot blasting M/c
Capacity - max.jobdia 1800mm,2500 kg
Max: axle box spring - 25nos
Bolster - 18nos