Training report on nwr carriage workshop, jodhpur

This training report is very useful for that every student who complete their summer training under NWR carriage Workshop,Jodhpur for fullfillment for the award of degree of B.Tech.

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 [phone]

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

9. 9

FULL TRAINING SCHEDULE (50 DAYS) BY RAILWAY BOARD:

10. 10

HIERARCHY IN Jodhpur Workshop

 Chief Workshop Manager (CWM)
Sh. N.S. Patiyal 

o MECHANICAL

Dy. Chief Mechanical Engineer (Dy CME)

Sh. Rajiv Avasthi



Works Manager (WM)

Sh. Lalit Sharma



Assistant Production Engineer (APE)


Sh. B.C. Soni


o ELECTRICAL

Dy. Chief Electrical Engineer

Sh. Vijay Choudhary



Workshop Assistant Electrical Engineer (WAEE)

Sh. R.P.Meena

o PERSONNEL


Dy. Chief Personnel Officer (Dy. CPO)

Sh. Pradeep Yadav


o FINANCE & ACCOUNT

Senior Assistant Finance Advisor (SAFA)



Assistant Finance Advisor (AFA)


o ENGINEERING


Executive Engineer (XEN) – Construction


o STORE
 Dy. Chief Material Manager (Dy CMM)

Assistant Material Manager (AMM)




o SUPERVISORS


Senior Section Engineer Incharge (SSE)



Junior Engineers (JE-I)


11. 11

BASIC
TRAINING
CENTER-
JODHPUR


TRAINING PERIOD:
27/05/17 – 15/7/17

12. 12

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. 1
st
Day-Remove old painting.
2. 2
nd
Day-One coat primer.
3. 3
rd
Day-One coat brush filler.
4. 4
th
Day-2
nd
coat filler with putty
5. 5
th
Day-Rub down with SiC paper
6. 6
th
Day-One coat of undercoat
7. 7
th
Day-Flat with SiC paper & apply one coat of enamel finish
8. 8
th
Day-Flat with SiC paper gr-400 & 2
nd
coat of synthetic enamel finish
9. 9
th
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/cm
2
.


Feed pipe throughout the length of train is charged with compressed air at 6
Kg/cm
2
.


Control reservoir is charged to 5 Kg/cm
2
.


Auxiliary reservoir is charged to 6 Kg/cm
2
.


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/cm
2


Brake release stage:

Brakes are released by recharging brake pipe to 5 Kg/cm
2
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 100
0
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 40
o
C to 50
o
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 120
0
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 120
o
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