PRESENTATION ONCARRIAGE AND WAGON SHOP

PRESENTED BY :AJEET KUMARROLL NO- 1112240014

ABOUT CARRIAGE AND WAGON WORKSHOP

• The Alambagh workshop, near Lucknow, was set up in 1865 by the Oudh and Rohilkhand Raiilway. It started off doing minor maintenance and periodic overhaul of coaches and wagons, and eventually became one of the top workshops engaged in overhaul, repair, and restoration of carriages and wagons. Today the workshop specializes in the new high-speed coaches (LHB Alstom, IR20/IRY, etc.), air-conditioned coaching stock, etc.

The Basic Data for workshop are as under• WORKSHOP AREA = 204684 Sq. Mtrs.• COVERED AREA = 72595 Sq. Mtrs.• POWER CONSUMPTION = 14666 KWH/day• WATER CONSUMPTION = 1575000 Ltrs./day

CONTINUED….

Major Shops

Train Lighting

AC Deluxe

Carriage Fitting

Carriage Building

Heavy Corrosion Repair

Bogie Lifting

Wheel Shop

Spring Shop

Common Shops

Minor Shop Major Shop

Paint Shop Mill Wright Shop

Road Transport Shop New Machine Shop

Yard Carriage Shop Carpentry Shop

Role of C&W workshop in Railways

A. Related with Open Line working :-

i) To ensure and co-operate in safer running of rolling stock.

ii) To attend required schedule maintenance & running repairs of rolling Stocks till the stocks are again due for P.O.H.

iii) To assist in time running of trains to maintain the punctuality.

B. Related with Work -Shop working :-

i) To attend Periodical Overhauling of Rolling Stocks.

ii) To adopt required modifications.

iii) To maintain proper records of all the rolling stocks running in Indian Railways.

CLASSIFICATION OF ROLLING STOCK

• Rolling Stock: - It is a term used for the stocks of coaching, freight (Goods) & Locomotive.

• Coaching Stock: - All coaching vehicles including self propelled units such as rail cars, electrical multiple unit, luggage & brake van fit to run with coaching stock are known as coaching stock.

• Goods Stock: - All goods stock other than coaching stock whether attached to passenger or goods trains are known as goods stock.

Vehicle: - It is a term used only for coaching stock. There are two types of Coaching Stock.

1) Passenger coaching vehicle (PCV): - A vehicle in which whole or partial portion is being utilized for carrying passengers.

2) Other coaching vehicle (OCV): Saloons, inspection cars, medical cars, tourist cars, parcels & horse van, composite luggage Power Cars, Pantry Cars & brake van are known as OCV.

Types Of Coaches

• ICF: Integral Coach Factory, Perambur (Chennai) & Rail Coach Factory, Kapurthala (Punjab)

• LHB COACHES: LHB body with FIAT bogie (Linke Holfmann Busch – German) Maximum Permissible Speed 160 kmph

.

Hybrid Coach: LHB Body on Modified ICF Bogie – Running in same of the Duranto Rake

Loco- Brief Data

Weight of complete loco-123 tons.

Weight of Loco body is 73 tons.

Weight of complete bogie is 25 tons each.

Load exerted per axle is 20.5 tons.

Weight of Traction motor is 3.80 tons.

Wheel set with gears is approx. 2.15 tons.

Manufacturing units

Coaches- Integral Coach Factory,Perambur,Chennai.

Rail coach factory, Kapurthala,Punjab.

Wagons-BEML(Bharat Earth Movers Limited).

Diesel components Workshop at Punjab.

Major workshops-

DLW(Diesel Loco Workshop) at Varanasi.

Chittaranjan Loco Workshop.

BHEL also manufacture on contract basis.

RDSO is the authentification Unit of railways.

TRAIN MAINTENANCE

Washing line :-

after every 2500 km

Sick line :-

Schedule “A” maintenance- 1 month

Schedule “B” maintenance- 3 months

IOH- 9 months or 2,00,000 km

POH- 18 months or 4,00,000 km

Platform Train Duty:-

on starting & ending stations

BRAKE TESTING IN WASHING LINEBrake testing is carried by using RTR (rack test rig)Rack testing rig is capable of testing full train (up to

24 coaches) at a time. 

SECONDARY MAINTENANCEThe trains for the secondary maintenance are given at

least 2 hrs on the washing lineLinen and pantry car provisionsWashing & cleaning of coachesMaintenance of AC of coaches

PRIMARY MAINTENANCEThe trains for the primary maintenance are given at least 6 hrs

at the washing line in addition to secondary maintenanceOil in hydraulic dash potsWheel profiles are visually examined and gaugedpest control treatmentAxle box is examined for grease oozing out from rear coverBrake blocks & piston stroke checked & changed

COACH MAINTENANCE

In coach maintenance generally these work being done

1. testing/maintenance of air conditioner.

2. Maintenance of other electrical circuits like fan light

etc.

3. Buffer maintenance.

4. Brake testing by S.C.T.R.

BUFFER MAINTENANCEBuffers are the horizontal shock absorbing parts with

coupling the adjacent coaches of the train so need regular changing of shock absorbing rubber pads.

BRAKE TESTING

Here S.C.T.R. use for testing of brake and its cylinder acts as the

main reservoir.

There are two pressure potentials i.e. 5kg/cm2 in brake pipe and

6kg/cm2 in feed pipe.

SEPARATION OF COACH & BOGIE After watching the inspection list if bogie needs

repair like filling of oil or changing of brake shoe etc. then bogie is separated from the coach by lifting through a crane

MAINTENANCE OF BOGIE

Maintenance processes done on the bogie such as replacement of the Brocken, wear out parts, replacement of pins and brake shoe, filling of oil in the suspensions, lubrication of different parts, tightening of different screws and bolts and change of axle & wheels if required.

MAINTENANCE OF SUSPENSION

In primary suspension mainly we have a spring and a dashpot to provide damping arrangement so regular refill of oil and changing of oil being done in the workshop

CHANGE OF DEFECTIVE WHEELS

Wheels of train are subjected to a no of defects i.e. reduce in the dia. of wheels, Reduce in size of flange, break of bearing in axle box

BRAKE MAINTENANCE

Brakes are the most important part of a train. The maintenance of brakes consists of change of brake blocks, adjust stroke length, change of brake cylinder, leakage in brake system etc.

AXLE BOX FEELING

After the train come to halt, all axle boxes are felt within 20 minutes. The temp. of axle is checked by touching with hand

Temp. is found high then it is checked by the temp. gun which gives exact temp.

If this temp. is found more than 30 degree than atm. temp. then the cause is inspected and coach is sent to workshop

COTINUED…

i) Quick Coupling in case of Brake Van.

j) Automatic empty load change over device in case of BOBR/BOBRN Wagons.

Use new rubber items for joints between pipe and equipment irrespective of condition of old items.

xiv) Properly secure nut and bolts of joints between pipe and equipment.

xv) Examine all pipe and pipe fittings and brackets and properly secure them.

Pipes should not be loose inside the pipe clamps.

xvi) Fit following APD :

a) Additional APD of DV.

b) APD of DV.

c) APD of Angle Cock

xvii) Fit overhauled Hose Couplings at both ends of Brake Pipe.

xviii) PAINTING

All items shall be painted black as per standard practice.

PERIODICAL OVERHAUL OF WHEEL ASSEMBLY

i. The dust shield should be examined, every time the axle box is repacked during POH. If found worn, torn, or if it has lost its stiffness, it should be replaced.

ii. Axle boxes should be examined and inspected on open lines for defects.

iii. The elongated/oval cut holes on face plate should not allowed. Proper

riveting of the face plate to be done with axle box.

iv. Bearing brass to be examined and repaired.

v. Repair of the journal to be done.

vi. Periodicity of repacking and oiling .

vii. Proper attention must be paid to the examination and riveting of the face plate at the time of POH in workshop.

ix. Procedure for white metalling to be done.

x. Examination and maintenance of Axle, wheels and tyres should be done.

Difference Between IOH, POH & NPOH Sl.No IOH POH NPOH

1 It stands for intermediate overhauling.

It stands for periodic overhauling. It stands for non periodic overhauling.

2 IOH of coach is attended after 9 months of POH.

POH of Passenger carrying vehicle M/Exp -18 months,

Time Period is not fixed for any vehicle for NPOH

3 IOH of coach is allowed in sick line where facility to lift the coach is available.

POH is allowed in nominated workshops only.

NPOH is done only in workshop or in nominated major sick line.

4 During IOH all the parts of under gear thoroughly examined and replaced if necessary.

At the time of POH all parts of under gear are dismantled and should be replaced if there is any wear and tear.

Only indicated defects & safety items are attended.

5 At the time of IOH painting of coach is not necessary, only required places are touched up.

Painting of whole coach is necessary. Complete painting of coach is not necessary, only required places are touched up.

6 Profiling of wheel is necessary 

Profiling of wheel is necessary. Profiling of wheel is on need based.

BOGIE-A brief description

4 wheel set is known as Bo-Bo type.

6 wheel set is known as Co-Co-CO type.

Former type is used as

COACH

GOODS WAGON

• Later type is used as LOCOMOTIVE

Comprises of bogie frame and the loco weight

mounted on it.

EQUIPMENTS in a Bogie

It comprises the Bogie

frame.

The bogie frame has the

Axle and wheel

arrangements.

The SUSPENSION

system.

The BRAKING system.

MAINTENANCE/INSPECTION

Various periodic inspections are made to

ensure proper functioning of the LOCO

• TRIP INSPECTION• MONTHLY INSPECTION• TWO MONTHLY NSPECTION• FOUR MONTHLY INSPECTION• YEARLY INSECTION• POH INSPECTION

POH inspection

It is accomplished either after 9

years or 9 lacs km.,whichever is

earlier.

Dismantling of bogie is done.

Parts are cleaned in acidic

solution for about four hours.

Axle box is checked for heating

up.

Evidence of cracks and other

defects are replaced.

Bogie Manufacturing

Initially done by Casting.

Generated cracks

Rate of success was 60 %.

replacement was difficult.

Fabrication is done now a days

Welding and Oxycutting is done.

Rate of success is 80 %.

replacement of parts is easy.

Bogie-Fuel Tank

Capacity of fuel tank- 5000 litres.

At full load, consumption is 325-365 litres/hour.

Average fuel consumption is 45 litres/hour at

standby mode.

Approximately, 5.5 litres/km.

bogie

A bogie is a wheeled wagon or trolley. In mechanics terms, a bogie is a chassis or framework carrying wheels, attached to a vehicle.

Usually the train floor is at a level above the bogies, but the floor of the car may be lower between bogies.

Bogies serve a number of purposes:

1. To support the rail vehicle body

2. To run stably on both straight and curved track

3. To ensure ride comfort by absorbing vibration, and minimizing centrifugal forces when the train runs on curves at high speed

Usually two bogies are fitted to each carriage, wagon or locomotive, one at each end. Most bogies have two axles as it is the simplest design, but some cars designed for extremely heavy loads have been built with up to five axles per bogie.

Key components of a bogie include:

1. The bogie frame itself.

2. Suspension to absorb shocks between the bogie frame and the rail vehicle body. Common types are coil springs, or rubber airbags.

3. At least one wheel set, composed of an axle with a bearings and wheel at each end.

4. Axle box suspension to absorb shocks between the axle bearings and the bogie frame.

5. Brake equipment. Two main types are used: brake shoes that are pressed against the tread of the wheel, and disc brakes and pads.