Summer Training in Mechanical Workshop Gorakhpur, Northern Eastern Railway.

1. INDUSTRIAL TRAINING PRESENTATION
ON
MECHANICAL WORKSHOP
NORTH EASTERN RAILWAY GORAKHPUR
Presented by:-WAJAHAT HUSSAIN
EN : 4th year
AKGEC

2. Overview of North Eastern Railway:
• The North Eastern Railway system passes through the states of
Uttar Pradesh, Bihar and Uttarakhand and runs from West to
East.
• Presently, North Eastern Railway has three Divisions at Varanasi,
Lucknow and Izatnagar. It has Headquarter at Gorakhpur.
• There are 498 Stations, two Mechanical Workshops (one each at
Gorakhpur and Izatnagar), two Diesel Sheds (one each at Gonda
and Izatnagar), one Engineering Workshop at Gorakhpur and one
Signal Workshop at Gorakhpur.
• Gorakhpur Railway station offers Class A railway station facilities.
On 6 October 2013, Gorakhpur railway station platform number 1
became the world's longest railway platform,with a stretch of
around 1.35 kilometres (0.84 mi).

3. Gorakhpur Junction

4. Overview of Mechanical Workshop:
Gorakhpur mechanical workshop is established in 1903 for repair
and over hauling purpose of steam locomotives.
This Workshop is used for periodic over hauling and maintenance
purpose of AC and NON AC coaches.
At present, this workshop is mainly carrying out POH of BG AC
and NON-AC coaches
The workshop having capacity to overhauled 180 coaches per
month.
Capacity augmentation and modernization project phase-1(costing
RS.22.7 crore) and phase -2(costing Rs.18 cr.) has been sanctioned
and are under progress.

6. LISTOF SHOPSINTHISWORKSHOP:
INSPECTION SHOP
MACHINE SHOP
PAINTING SHOP
WHEEL AND SHAFT SHOP
SPRING SECTION
HEAT TREATMENT SHOP
JIG AND FIXTURE
AC SHOP
FURNISHING SHOP

7. STAISTICSANDSPECIFICATION:
1.No of officers -19.
2.No of supervisors-378.
3.On roll strength- 5282.
4.Total area covered-29.8 Hectare.
5.Covered area-12.6 Hectare.
6.Township area Gorakhpur.
7.Power consumption- 208662KWH.

8. Paint Shop:

9. Coach Shifting Machine-

10. • It's capacity is about 70tonnes.
• It uses a power supply of 415V,3phase at 50Hz.
• Motor used is Synchronous motor which has squirrel type
rotor with speed 1000rpm/1500rpm.
• Power required is about 75KW.

11. AC Shop-

13. HISTORY OF AC COACHES
 The first Indian air-conditioned train was Frontier Mail which
was introduced in 1934. Earlier, the AC coaches of the train
were kept cool by using ice blocks. These were replenished
at several halts along the line. A battery operated blower
constantly blew air into these receptacles, and the cold air
entered the insulated cars through vents.
 The first fully air-conditioned train was introduced in 1956
between Howrah and Delhi. Popularly known as the AC
Express.

14. The following are the various maintenance schedules carried out
on air-conditioned coaches.
• Trip schedule.
• Monthly schedule.
• Quarterly schedule.
• P.O.H.

15. AIR CONDITIONING
Air conditioning (often referred as AC) is the process of
removing heat and moisture from the interior of an
occupied space, to improve the comfort of occupants. Air
conditioning can be used in both domestic and
commercial environments.
Air conditioning is a type of refrigeration where thermal
energy is taken away from the air in a large space such
as a room or a vehicle.

16. REFRIGERANT
 A Refrigerant is a fluid/gas/liquid that is employed in the
Air Conditioning systems and Refrigerators. Without
refrigerant, Air Conditioners will not work.
 R-22 is the most common refrigerant that is used in the air
conditioners. In the late 1990s, the CFCs were replaced by
Hydrochlorofluorocarbons. R-22 is the refrigerant that is
used in more than 50% of Air Conditioners in India (As of
now).
 As of now, the most environment-friendly refrigerants
available for Air Conditioners in India are R-290 (Propane)
and R-600A (Iso-Butane).

17. AIRCONDITIONED COACHES

18. AC EQUIPMENT IN RAILWAY COACHES
1)Evaporator Unit.
2)Compressor.
3)Condenser Unit.
4)Gauge panel.
5)A/C control panel.
6)Wiring.
7)Expansion valve.

19.  Compressor – compresses & delivers gas into
condensers at a high pressure & high temperature.
 Condenser – it cools the hot gas and liquidities under
pressure.
 Evaporator –the cooling unit in which liquid freon under
low pressure evaporates & in-doing so takes away the
latent heat thereby cooling the medium surrounding the
cooling coil.
 Gauge panel -consists of pressure gauges (HP, LP,
and OP) and pressure cutouts to protect the
compressor.

20. AC Control panel-The control of the airconditioning
system is achieved by means of air conditioning control
panel.
Expansion Valve – It controls and regulates the rate of
flow of liquid freon under high pressure.

21. ROOF-MOUNTED PACKAGED UNIT(RMPU)
To overcome drawbacks of under-frame open type AC
systems – RMPU of 5.2 TR each was introduced in the
year 1992.
Light weight & reliable.Uses more environment friendly
refrigerant R-22 and very small quantity less than 3 Kg.
Energy efficient - uses less electricity, saves fuel for
generation.
Light weight & reliable.

22. RMPU TOP VIEW

23. SG COACHES
2×25 kW alternators for AC coach and 1×4.5 kW for non-
AC coach is mounted underslung, driven by a pulley-belt
arrangement when driving pulley is mounted on coach axle.
Output is rectified and charges 110V DC battery for
continuous power supply to AC and non-AC coaches. AC
load of roof mounted packaged units is supplied by
converting DC into 2×25 kVA inverters. This system is
followed over trains having a combination of AC and non-
AC coaches.

24. • The alternator is totally enclosed, hetropolar induction type
machine having no winding on the rotor. It has no sliding
contacts like brushes, slip ring commutators etc; offering robust
construction suitable for severe shocks and vibrations
encountered in Railway services.
• The alternator consists of two sets of windings viz. AC winding
and field winding. Both accommodated on the stator. The AC
windings are distributed in the small slots and field windings are
concentrated in two slots. Each field coil span is half of the total
number of stator slots.

25. Alternator Particulars:
a. Rated capacity 4.5 KW
b.No Load to full load voltage range 120 V to 124 V
c. Cut-in speed 300 rpm
d.MFO speed 550 rpm
e. Max. Permissible speed 2540 rpm
f. Drive/Mounting Belt/Transom
g.Overhaul length 690.25  5 mm
i. Overhaul dia 285 mm
j. Weight of alternator without pulley 194.5 Kg

26. Alternator Testing Machine-

27. TEST ON ALTERNATOR:
• Measurement of stator resistance of alternator
• Temperature rise test
• Insulation resistance test
• High Voltage test
• Open circuit test
• Load test on Alternator with Controller
• No load test
• Hose proof test
• Battery charging current limiting test

28. No load DC Output voltage 135 V (Maximum)
DC Output Voltage setting 129 ±0.5 V, 115A at 110 kmph
Voltage regulation ±2% of set voltage
Voltage ripple within 2%
Load variation 10 A to 230
Speed variation 0 to 145 kmph
Voltage at 10% over load 120 V (minimum) at 250 A
Current limiting 250 A at 120V
Battery charging current limits (max) 120 A to 130 A

29. V-Belt:
• V-belts (multiple drive) are used for transmission of
mechanical power from the coach axle to the alternator which
supplies power to the train-lighting and air conditioning loads
in Railway coaches.
• The reliability of the V-belt is essential to ensure that there
is no breakdown in the passenger amenities, viz. lighting, air
conditioning and air circulation devices i.e. fans in the railway
coaches.
• Railways are using C-122/3155 Lp V-belts as per RDSO
specification

31. Power to be transmitted 4.5 KW/12KW/25 KW
Minimum speed for full output 4.5 KW 12 KW 25 KW
600 rpm 900 rpm 800 rpm
TESTS:
1. Visual Inspection
2. Marking
3. Pitch length measurement
4. Angle checking
5. Section checking

32. Battery and Battery Charger:
The entire coach load is met by the battery of 800AH
capacity,during stationary or when the coach is running at less
than MFO( minimum full load output) speed.
Provision for charging and precooling the coach from external
supply has been made by means of battery charger, 200Arating
mounted on the coach under frame
The battery charger takes 415 V 3 phase supply through
special battery charging sockets mounted diagonally one
on each end wall.
The battery charger consists of a transformer and a simple
diode bridge rectifier.

33. All these tests shall be started after 3 cycles of charge/discharge at
10 hour rate. All these tests shall be conducted at 27  5ºC unless
and otherwise specifically mentioned.
a)Capacity at 10 hrs rate (clause 5.13).
b)Watt-hour and Ampere-hour efficiency tests according to Clause
5.14. Watt hour efficiency shall not be less than 80% and Ampere
hour efficiency shall not be less than 93%. While conducting this
test a minimum rest of 12 to 24 hours shall be given between each
charge/discharge.

34. c)Initial cranking current (clause 5.16).
d)Sustained cranking current (clause 5.17).
e)Resistance to over charge (clause .5.19).
f)Storage test as per Clause 5.22.
g)Electrolyte retention test according to clause 5.23
h)Loss of water as per Clause 5.9 of this Spec.
i)Vibration test: as per clause no.5.10.

35. THANK YOU