Harnaut mechanicaL workshop summer training repoRT

VOCATIONAL TRAINING REPORT OF CARRAIGE REPAIR WORK SHOP HARNAUT

1. EAST CENTRAL RAILWAY HARNAUT (BIHAR)
INDUSTRIAL TRAINING REPORT 2016-17

K.K. COLLEGE OF ENGINEERING AND
MANAGEMENT BIHAR SHARIF
(NALANDA),BIHAR

SUBMITTED BY-
NAME-ROHIT BHARTI
ROLL NO. 13ME06
BRANCH-MECHANICAL ENGG.

ACKNOWLEDGEMENT

2. Mechanical workshop of north eastern
railway, Gorakhpur is a well-known public
sector industry. I am deeply grateful to Chief
Workshop Manager, Who gave me a chance
to have an insight of the vocational training of
four weeks.
By seeing the good management of the plant,
I learnt a lesson three D’s Discipline,
Determination and Devotion .I also grasp an
idea of state-of-the-art technology and plant.
I am also grateful to each of my chief-
instructor MR.SANJIV KUMAR SHARMA
SSE/BTC/CRW/HRT who provided me every
help and removed my doubts about the
particular shop.
NAME –ROHIT BHARTI
DATE-25/07/2016

3. LIST OF CONTENT
1. INTRODUCTION OF INDIAN RAILWAY
2. MACHINE SHOP
3. PAINTING SHOP
4. WHEEL SHOP
5. SPRING SHOP
6. HEAT TREATMENT SHOP
7. JIG AND FIXTURE SHOP
8. BRAKING SYSTEM
9. SHELL SHOP
10. MATERIAL HANDLING SYSTEM
11. REFERENCES

4. INTRODUCTION

Indian Railways is an Indian state-owned enterprise,
owned and operated by the Government of
India through the Ministry of Railways. It is one of the
world's largest railway networks comprising 115,000 km
(71,000 mi) of track over a route of 65,436 km
(40,660 mi) and 7,172 stations. In 2013–14, IR carried
8,425 million passenger’s annually or more than 23
million passengers daily (roughly half of which were
suburban passengers) and 1050.18 million tons of
freight in the year. In 2013–2014 Indian Railways had
revenues of 1441.67 billion (US$23 billion) which
consists of 940.0 billion (US$15 billion) from freight
and 375.0 billion (US$6.1 billion) from passengers
tickets.
Railways were first introduced to India in the year 1853
from Bombay to Thane. In 1951 the systems were
nationalised as one unit, the Indian Railways, becoming
one of the largest networks in the world. IR operates
both long distance and suburban rail systems on
a multi-gauge network
of broad, metre and narrow gauges. It also
owns locomotive and coach production facilities at

5. several places in India and are assigned codes
identifying

Their gauge, kind of power and type of operation. Its
operations cover also provides limited international
services to Nepal, Bangladesh and Pakistan.
Indian Railways is the world's seventh largest
commercial or utility employer, by number of employees,
with over 1.307 million employees. As for rolling stock,
IR holds over 239,281 Freight Wagons,
62,924 Passenger Coaches and 9,013 Locomotives (43
steam, 5,345 diesel and 4,568 electric locomotives). The
trains have a 5 digit numbering system and runs 12,617
passenger trains and 7421 freight trains daily. As of 31
March 2013, 20,884 km (12,977 mi) (31.9%) of the total
65,436 km (40,660 mi) route length was electrified,
Since1960, almost all electrified sections on IR use
25,000 Volt AC traction through overhead catenary
delivery.
DIVISION IN INDIAN RAILWAY
The Indian Railways is divided into zones, which
are further sub-divided into divisions, each having
a divisional headquarters. There are a total of
sixty-nine divisions.
Each of the divisions, is headed by a Divisional
Railway Manager (DRM) who reports to the
General Manager (GM) of the zone. A DRM can
be appointed from any services of Indian railway,
Indian Administrative Service (IAS) and Indian
Revenue Service (IRS) for the tenure of 3 years

6. but it can be exceeded on the recommendation of
Railway Board.
Divisional officers heading all departments viz.
engineering, mechanical, electrical, signal and
telecommunication, accounts, personnel,
operating, commercial, safety, medical, security
branches report to the Divisional Railway
Manager. The DRM is assisted by one or two
Additional Divisional Railway Managers (ADRM) in
the working of the division.
There are seventeen main division in Indian
railway listed below….
1. Central railway-CR- Mumbai
2. East central railway-ECR- Hajipur
3. East coach railway-ECoR- Bhubaneswar
4. Eastern railway-ER- Kolkata
5. North central railway-NCR- Allahabad
6. North eastern railway-NER- Gorakhpur
7. North western railway-NWR- Jaipur
8. North east frontier-NFR- Guwahati
9. Northern railway-NR- Delhi
10. South central –SCR- Secunderabad.
11. South eastern-SER- Kolkata
12. South western –SWR- Hubli
13. Southern railway-SR- Chennai
14. South east central-SECR- Bilaspur
15. West central railway-WCR- Jabalpur
16. Western railway-WR- Mumbai

7. 17. Kolkata Metro- Kolkata

ABOUT GORAKHPUR MECHANICAL WORKSHOP
Gorakhpur workshop was established in 1903 for repair
and overhauling of MG steam locomotives, coaches
and wagons. Due to gauge conversion from MG to BG,
POH activity of 50 BG coaches /month was started in
sep1984.The POH of MG coaches was also stopped
from January 2002.At present, this workshop is mainly
carrying out POH of BG AC and NON-AC coaches in
number 180 per months. Capacity augmentation and
modernization project phase-1(coasting RS.22.7 crore)
and phase -2(coasting Rs.18 cr.) has been sanctioned
and are under progress.
STAISTICS AND SPECIFICATION
1. No of officers -19.
2. No of supervisors-378.
3. On roll strength- 5282.
4. Total are covered-29.8 Hectare.
5. Covered area-12.6 Hectare.
6. Township area Gorakhpur.
7. Power consumption- 208662 KWH.

8. MACHINE SHOP
In this section all kinds of machining is done to obtain
the correct size and shape of the job. Besides,
machining of steel job, Aluminum-plates are also
machined here. Machining is other performed
manually or on automatic machines.
Machines are two types…
1. AUTOMATIC.
2. MANUALLY.
There are three types of automatic machine.
1. Numerical control.
2. Computer numerical control.
3. Direct numerical control machine.
NUMERICAL CONTROL-The machining parameter are
feed from the control panel by pushing buttons .The
job is machined according to the parameter There are
N.C. boring machine in this shop.
COMPUTER NUMERICAL CONTROL- In this machine all
the data corresponding to the initial work piece to the
final product is feed into the computer. All the process
required in the order of action is fed with the help of
programmer .In this machine one, has to just fix the job

9. is to the chuck. All the other process is done
automatically. This is the machine use for large scale
production. In this shop there is one CNC chucker
turret Lathe machine.
DIRECT NUMERICAL CONTROL-This machine is
controlled by installing a control room away from the
work place .These machine are D.N.C. machine. These
are fully automated .The machine shop is divided into
different divisions to the task accomplished .Theses
sections are-
1. Capstan and turret lathe section.
2. Milling section.
3. Drilling section.
4. Central lathe section.
5. Heavy machine section.

10. MANUALLY OPERATED MACHINE
DRILLING SECTION-Drilling operation is carried out
here. A large for the operation .To complete the
operation faster a few gauge milling machine are also
provides.

DRILLING MACHINE

CENTER LATHE SECTION-Heavier lathes are provided
in this section. All the lathes have four jaws chuck for
better holding centering is done either manually or
with the help of universal scriber. All kinds of turning
are performed here. Parting off is other major
operation done.

11. LATHE MACHINE
SHAPER-The machine is also called horizontal
shaping machine. It works on quick-return
mechanism .The arm of shaper reciprocating
horizontally. The cutting
take place only in the forward stroke. The bed
of the machine is fixed and the tool reciprocating.
Shaping, Planning, Grooving etc are performed by
this machine.

12. SHAPER
SLOTTER-The is vertical shaping machine .The arm
reciprocating in the vertical direction .Most parts are
the same as shaper .Slotting is the process that is
carried on this machine .

13. N.C.BORING-By this boring machine, various different
operations can be done such as drilling machine etc.
The depth of cut and the feed is controlled by pushing
the button of control panel. The fig.is displayed while
machine, the work table rotates and the tool is fixed.
PLANNER-Planner is used for the very large jobs. The
basic difference between shaper and planner is
procedure of giving relative motion between the work
piece and tool .In the shaper, the tool reciprocates
while in planner the table reciprocates.


PLANNER

14. PAINT SHOP
The Work of this shop is to paint the coaches and
bogie.
In this shop there are many sections and they are
following –
1. COACH PAINTING.
2. LETTER SECTION.
3. TRIMMING SECTION.
4. CORROSION SECTION.
5. POLSIH SECTION.
PURPOSE OF PAINTING-
1. FOR PROTECTION AGAINST COROSION.
2. FOR DECORATION.
3. FOR COVERING.
MATERIAL USED IN PAINTING –
1. PAINT MATERIALS.
2. ENEMAL MATERIALS.
3. VARNISH MATERIALS.
4. LACQUER MATERIALS.
PAINT MATERIALS-
1. BASE.
2. BINDER.
3. THINNER.

15. 4. DRIER.
5. PIGMENT.
6. INERT OR FILLER MATERIAL.

PAINT BOX

THINNER
THE MAIN PROCESS INVOLVE IN PAINTING – Firstly,
Putin is prepared and it gets filled at the places where
holes and cracks has been found.
Secondly, the primer is put on the body and then
finally painting is done in order to give the body desire
shape.

16. The overhauling of the coaches has been in given time
interval it improves the quality of coaches and it also
prevents the coaches from break down. The
maintenance of coaches is according to time being is
done as following-
1. MAIL EXPRESS- 12 MONTHS.
2. PASSENGER- 18 MONTHS.
3. NEWLY COACHES- 24 MONTHS.

TYPES OF PAINT-
1. Aluminum Paint.
2. Anti-corrosive.
3. Asbestos paint.
4. Bituminous paint.
5. Cellule paint.
6. Cement paint.
7. Distemper.
8. Plastic paint.
9. Graphite paint.
10. Oil paint
11. Silicate paint.
12. Luminous paint.
13. Enamel paint.
14. Emulsion paint.

17. WHEEL SHOP
In this shop, repair work of the wheel and axel is
under taken. As it is known that, the wheel wears
throughout its life. When at work the profile and
diameter of the wheel constantly changes. To
improve it’s working and for security reason, it is
repaired and given correct profile with proper
diameter.
The diameter of new wheel is-
Type Wheel
dia.
Distance
b/w
journal
center
(mm)
Journal
size(mm)
Axel wheel
seat dia.
(mm)
ICF 915 2159 120*113.5 172,0.25,0.35
BMEL 915 2210.2 120*179 171,0.45,0.63

Wheel can be used certain minimum diameter after
which it is discarded. The diameter of the wheel
when it is condemned are-
S.N TYPE OF WHEEL DIAMETER IN (MM)
1. ICF/BMEL SOLID 915-813
2. ICF TIRED 915-851
3. BMEL TIRED 915-839

18. WHEEL
WHEEL TESTING & MACHINING
In this shop wheel sets are removed from the bogies,
the entire wheel is first inspected for assessing the
condition of the component of wheel such as axel
trial wheel disc and guttering.
The shop consist of-
(1) Axel journal testing lathe.
(2) Hydraulic wheel press with facility of mounting.
(3) Axel turning lathe.
(4) Vertical turning lathe.

Axel journal turning lathe.
On this lathe, the diameter of the axel is brought to the
correct diameter. The cutting tool is used of carbon
tool.

19. Hydraulic wheel press with a facility of mounting.
The wheel is pressed on the axel with the help of this
machine. A calculated amount of pressure is applied
and the wheel is pressed.
Axel turning machine.
External and internal diameter is corrected by this
lathe, wheel is tightened on the rotating clutch. The
stationary is carbide tool cut the wheel to correct
diameter.
Wheel Profile Lathe.
The profile of the wheel is repaired on this machine.
Correct profile is cut by carbide tool.
ZYGLO TESTING
It is a non-destructive testing is used to detect the
flows or discontinuities in materials without using
impairing their use fullness. This testing is used for
ferrous is non-ferrous metals.

ZYGLO TESTING MACHINE.

20. SPRING SECTION
In this section the helical and leaf spring are prepared.
For this purpose there certain machine for testing,
grading and repairing it.

SPRING
The test performed on helical spring and laminated
spring are-
(1) Visual and magnetic crack detection.
(2) Spring scraping machine.
(3) D’ buckling
Visual and magnetic crack detection. The visual test
with the help of magnifying lens and glass the spring
the is inspected of-
Corroded--------------- Fail
Deep seam of mark -------------------- Fail
Surface crack ------------- Fail
No sound defect ------------- Fail

21. In the magnetic testing a mixture of kerosene oil and
magnetic red ink is sprayed on the spring and
inspected for the clinging of the oil droplets. If oil clings
at same place if present the presence of crack. There
are variation reasons for the failure of the helical
spring such as free height load test, dent mark,
corrosion and breakage.
CAUSE PERCENTAGE OF FAILURE
Free of height 8.93%
Load test 82.08%
Dent mark, corrosion &
breakage
08.39%

SPRING SCRAGING
After the buckling test, the spring should be put on
scraping machine and the camber should be measured.
In this test, the spring should be pressed quickly and
camber should be measured 2 times. The spring should
be test such as, it should not be more than ½ of the
plate. In helical spring scraping, the spring is kept on
the machine and its free height us measure. Now the
spring is compressed, under certain and its
compression is noted down. The compression is
matched from the table provided for springs. If the

22. compression matches, the spring is passed otherwise
rejected.
VARIOUS REASONS OF SPRING FAILURE ARE AS
FOLLOW-
1. Over camber of the spring.
2. Short camber of the spring.
3. Leaf broken.
4. Gap between the leaves of the spring.
D’ BUCKLING
On this machine, buckling is performed on laminated
spring. The leaves of the springs are assembled and
pressed. Now it is put on the buckling machine axial
and longitudinal forces are applied.
VARIOUS OTHER MACHINES IN THIS SECTION-
1. Quenching tank.
2. Tempering furnace.
3. Rolling machine.
4. Cambering and hardening.
5. Hardness testing machine.
In hardness the use Brinell hardness test machine.

24. JIG AND FIXTURE SHOP
If a component to be produced in small numbers
then procedure adopted is marketing out, setting on
machine, clamping to machine table. Nevertheless. It
would not be suitable for producing same
component in large quantities because of economic
reason. A faster and more profitable method calls for
a device JIG&FIXTURE.
JIGS
Jig may be described as a plate, or metal box,
structure or a device usually made of which metal is
clamped or fastened or located one after others for
the other for specific operation in such a way that it
will guide one or more cutting tools to the same
position.
FIXTURE
This may be structure for locating holding and
supporting a component or work piece securely in a
definite position for a specific operation but it does

25. not guide the cutting tool. The cutting tool are set in
position by machine adjust or by trial& error
method.



FIXTURE
DESIGN OF JIG& FIXTURES
1. Sharp corners may be avoided.
2. Adjustment locator must be provided.
3. Locating pins should be tapered.
4. Quick acting, clamps should be provided.
5. Safety criterion should be provided.

26. 6. Accuracy is the basic need should not be
compromised.



BRAKING SYSTEM
Working-By means of frictional force between wheel
and brake pad.
Mainly two types of braking system is used-
1. Air-Braking system.
2. Vacuum-brake system.
AIR BRAKING SYSTEM
This is new method of braking system, which is more
efficient than the vacuum brakes. It is used at first in
Rajdhani and satabdi coaches. Progress conversion of
vacuum brakes in air-brake has being undertaken.
The main parts of air-brake system are following-
1. Brake cylinder.
2. Brake pipe.
3. Feed pipe.
4. Distributer pipe.
5. Angle lock.
6. House pipe.

27. 7. Auxiliary reservoir.
8. Guards van valve & pressure gauge.
9. Isolating cock.
10. Passenger emerging alarm signal device.
11. Dirt collector.

Description of some important parts of air-braking
system-
BRAKE CYLINDER-There are two 355 mm 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 distributor valve on one side and by
pivot to the block cylinder.

28. BRAKE PIPE-This is charged from the locomotive at 5
kg/cm3 and causes application and release of brakes
due to change in its pressure through the locomotive
control system. The pipe linked to distributor
system.
FEED PIPE- It having 6kg/cm3 pressure, and keeps
the auxiliary reservoir charge at fuel pressure even
when brakes are applied. Feed pipe are also
connected to the distributor valve.
DISTRIBUTOR VALVE- It is connected to the brake
pipe auxiliary reservoir and brake cylinder. It controls
the pressure in the brake cylinder. It controls the
pressure in the brake cylinder in proportion to the
reduction of pressure in brake-pipe.
ANGLE COCK-It is use for alarming purpose.
HOUSE COUPLING- Both the brake-pipe and feed
pipe are fitted to the angle cock outlet for the
passage of compressed air from one coach to
another mean of braided rubber and metal coupling.
GUARD VAN VALVE & PRESSURE GAUGE- These are
provided in the guards compartments. These are
provided to control the train movement.
ISOLATING COCK- Use for isolating the air from one
point to the other point.

29. CHOKE- It is device for restricting the flow of air from
one point brakes circuit to other point. The handle of
this cock is kept parallel to the pipe to indicate that it
is in open conditions.

SHELL SHOP
Shell shop is divided into two parts-
1. FITTING SHOP.
2. WELDING SHOP.
CAUSE OF CORROSION-
1. WATER SLEEPAGE.
2. AIR-TRAP BETWEENFLOOR AND PLYWOOD.
3. FLYING BLAST (DUE TO FORMATION OF SPOT).
MAIN PARTS OF SHELL- Various parts of shell are as
follows-
1. UNDER FRAME
(A)SOLE BAR
(B)HEAD STOCK ASSEMBLY.
(C)BODY BLOSTER ASSEMBLY.
(D)THROUGH FLOOR.
(E)CROPS BEARER.
(F)TUBULAR STRUCTURE.

30. 2. SIDE BAR.
3. ROOF.
4. END BAR.
5. CENTER PIVOT (GUIDE OF TURNING OF TRAIN).
TYPES OF WELDING USED IN SHELL SHOP-
1. CO2 ARC WELDING.
2. MANUAL METAL ARC WELDING.
3. BHARAT CUTTING GAS.(B.C.G)
4. LIQUEFIED PETROLEUM GAS.
5. OXY-ACETELENE GAS WELDING.

Welding by torch

31. MATERIAL HANDLING SYSTEM
Material Handling is the field concerned with
solving the pragmatic problems involving the
movement, storage in a manufacturing plant
or warehouse, control and protection of
materials, goods and products throughout the
processes of cleaning, preparation,
manufacturing, distribution, consumption and
disposal of all related materials, goods and their
packaging .The focus of studies of Material
Handling course work is on the methods,
mechanical equipment, systems and related
controls used to achieve these functions.
The material handling industry manufactures
and distributes the equipment and services
required to implement material handling

32. systems, from obtaining, locally processing
and shipping raw materials to utilization of
industrial feed stocks in industrial
manufacturing processes. Material handling
systems range from simple pallet rack and
shelving projects, to complex conveyor
belt and Automated Storage and Retrieval
Systems (AS/RS); from mining and drilling
equipment to custom built barley malt drying
rooms in breweries. Material handling can also
consist of sorting and picking, as well
as automatic guided vehicles.
MATERIAL HANDLING EQUIPMENT -
Material-handling equipment is equipment that
relate to the movement, storage, control and
protection of materials, goods and products
throughout the process of manufacturing,
distribution, consumption and disposal. Material
handling equipment is the mechanical
equipment involved in the complete system.
Material handling equipment is generally
separated into four main categories: storage and
handling equipment, engineered systems,
industrial trucks, and bulk material handling.

33. OVER HEAD CRANE


BELT CONVEYER

34. SMALL INDUSTRIAL TRUCKS






REFERENCES
1. www.wikipedia.org
2. www.slideshare.com
3. V.B. Bhandari.
4. Google images.

35. 5. John Wiley & sons.
6.Nptel lectures.
7.Ghosh& Malik.
8.Indianrailway.org.in