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EASTERN RAILWAY

CARRIAGE & WAGON WORKSHOP, LILUAH

An ISO-9001:2008 & ISO-14001-2004 Certified Organization

PROJECT ON VOCATIONAL TRAINING (From 29/06/2015 to 11/7/2015)

Submitted By

KESHAB PATRA

MECHANICAL ENGINEERING, B.Tech (4TH YEAR).

HERITAGE INSTITUTE OF TECHNOLOGY,KOLKATA

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CONTENTS

Sr. No Topic Page No

1. Introduction 4

2. E(Spring)-Shop 5

3. TR(Tool)-Shop 7

4. CTRB(Bearing)-Shop 8

5. C(Phosphate)-Shop 10

6. Air Break 11

7. M-Shop 12

8. MR(LHB)-Shop 13

9. A (Forging)-Shop 20

10. H-Shop 21

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Acknowledgement

This vocational training (29th June-11th July,2015)was attended to

develop a better understanding of Industrial Work in accordance

to the curriculum set up by

,approved by AICTE.

The Indian Railways gives me a great platform to hone the

skills with its immense workstations at C & W Workshop, Liluah,

Eastern Railway.

I would like to thank to CWE, Liluah, ER ; Training

Coordinator, BTC to grant me this opportunity.

KESHAB PATRA

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Introduction

The main activity of Liluah workshop is Periodic Overhauling &

Intermediate Overhauling of AC & Non-AC Coaches.it is one of the 3 pioneer

workshop of Indian Railway to do POH/IOH of LHB Coaches

The Workshop is presently engaged with the following activities.

POH & IOH of Eastern Railway coaches-AC and Non-AC including

new generation coaches like LHB, Hybrid, Double Decker.

Refurbishing of coaches both AC,Non-AC.

Retro fitment of Environment friendly Bio-Toilet in Coaches.

Renovation of NAC Pantry Car inCoaches.

POH & NPOH of air brake

wagons(BOXN,BOXNHS,BCN,BCNA,BCNAHS,BVZI)

Metallurgical and Chemical Laboratory:

Non-destructive testing including Ultrasonic testing of axles & wheels.

Chemical analysis and Physical testing of ferrous & non-ferrous

materials and oils, lubricants, paints, varnishes, rubber etc.

Failure investigation of rolling stock components.

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In railways helical springs are used in suspension system in different types

of coaches and wagons in different Nos.

In this shop periodical maintenance of different types of coil spring used in

coaches and wagons is done in accordance with RDSO specification with

accurate colour coding.

Coil Spring:-

A coil spring is actually a helical spring, is a mechanical

machine element,which is typically used to store

energy due to resilience and subsequently release it or to maintain a force

between contact surfaces.

Washing of spring in Bosch tank

Bosch Tank consists of 400 liter of water,16 Kg Caustic

soda,8Kg of Soda Ash,4.8 Kg of T.S.P,3.2 liter of liquid soap.

Springs are dipped into the tank for 6 Hrs (Cold solution) and 4 Hrs

(60 Deg Centigrade Hot).Then washed by spraying of high pressure

water jet and dried there. Defective springs are rejected by manual

inspection

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Shot Blasting Machine

In this machine springs are further cleaned by blasting high

velocity(180 m/s) sand & Alloy Steel particle.

Magnetic Crack Detecting Machine

Surface cracks and subsurface cracks are detected in this machine

by magnetizing the spring, magnetic particle and UV Lamps and

induced voltage tests.

Load Testing Machine

In this machine stiffness of the spring is determined in accordance

with the specified load and categorized them into three types.

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TR SHOP(Machine & Calibration Tools)

TR Shop basically deals with various machine and calibration tools.

This shop contains center lathe, turret lathe ,milling machine, planner

machine grinding machine etc.

Calibration means checking of instrument under test with a standard

instrument. These shop contains pressure gauge, filler gauge,slip

gauges,torque wrench tester,wheel diameter tester etc.

All gauges,templetes ,Jig fixures,Die punch(cold) as per drawing in general

fitting shop.

Centre Lathe Micrometer

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CTRB-SHOP(Cartridge taper Roller Bearing)

COMPONENTS OF CTRB : I. Outer Race or Cup

II. Inner Race or cone

III. Spacer Ring

IV. Tapered Rollers

V. Cage

VI. Grease Seal

VII. Wear Ring

PROCESS IN CTRB SHOP :

The components of CTRB unit is first dismantled in in the dismantling unit.

Due to long exposure grease gets hardened.So first the unit is dipped in

Kerosene oil to soften the grease.

Stripping of grease through centrifugal action.

Final cleaning with oil and compressed air jet.

Checking the components for cracks in different ways.

Checking the dimensions of different component with its standard value.

Greasing and assemble in the specified way.

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DEFECTS OF BEARING UNITS :

Sl. No

Damaged Condition

Possible Cause Remedy

1. Flaking Entry of foreign particles, water & poor lubrication.

Improve sealing mechanism, use lubrication with proper grade

2. Peeling Rough surface due to poor lubrication, entry of debries.

Use proper lubricant, Improve sealing mechanism.

3. Scoring excessive load, shaft bending Check the size of load, check the precision of shaft.

4. Smearing High speed & light load, sudden acceleration/deceleration.

Improved the preload, check bearing

clearance.

5. Fracture Impact during mounting, poor handling.

Improved mounting method, provide enough backup & support to bearing rib.

6. Cracks Heat generation due to creep, excessive interference

Correct the interference

7. Cage Damage

Poor mounting, excessive rotation speed, shock and large vibration.

Check mounting method, check the

rotation & load condition, reduce vibration

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C(Phosphate Coating) – SHOP

OBJECTIVES - Phosphate coating are used on steel part for

1)corrosion resistance , 2)lubricity , 3) foundation for subsequent coating or painting

PROCESS – The application of phosphate coating makes use of phosphoric acid

and takes advantage of the low solubility of phosphates in medium or high pH

solutions. Iron, zinc or Mg-phosphate salts are dissolved in a solution of

phosphoric acid. When steel or iron parts are placed in phosphoric acid, a classic

acid and metal reaction takes place which locally depletes the hydronium ions,

raising the pH, and causing the dissolved salt to fall out of solution and

participated on surface. The acid and metal reaction also creates iron phosphate

locally which may also deposited. In the case of depositing zinc phosphate or

Mg-phosphate the additional iron phosphate is frequently an undesirable addition

to the coating.

The acid and metal reaction also generates hydrogen gas in the form of tiny

bubbles that adhere of the metal. These prevent the acid from the reaching the

metal surface and slows down the reaction. To overcome this sodium nitrite is

frequently added to act as an oxidizing agent that reacts with the hydrogen to

form water. This chemistry is known as a nitrate solution. Hydrogen is prevented

from forming a precipitating layer on the surface by the oxidant additive.

POWDER COATING : Steps in powder coating

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Air Brake System

A railway air brake is a railway brake power braking system with compressed air as the

operating medium.

Railway air brake systems serve two functions:

The service brake system, which applies and releases the brakes during normal

operations, and

The emergency brake system, which applies the brakes rapidly in the event of a

brake pipe failure or an emergency application.

When the train brakes are applied during normal operations, the engine operator makes a

"service application" or a "service rate reduction”, which means that the train line

pressure reduces at a controlled rate. It takes several seconds for the train line pressure to

reduce and consequently takes several seconds for the brakes to apply throughout the

train. In the event the train needs to make an emergency stop, the engine operator can

make an "emergency application," which immediately and rapidly vents all of the train

line pressure to atmosphere, resulting in a rapid application of the train's brakes. An

emergency application also results when the train line comes apart or otherwise fails, as

all air will also be immediately vented to atmosphere.

Brake Pressure & Operation :

The compressor on the locomotive charges the main reservoir with air at 6 Kg/cm2. The

train brakes are released by admitting air to the train pipe through the engineer's brake

valve. A fully charged brake pipe is typically 5Kg/cm2. When brakes are applied it causes a

reduction in pressure in the brake pipe. In normal braking, the pressure in the train pipe

does not reduce to zero. If it does fall to zero, (e.g., because of a broken brake hose)

an emergency brake application will be made.

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M-SHOP (WORK- Heavy corrosion work) Types Of Coaches:

ICF RCF BEML LHB

Different parts LOAD DISTRIBUTION

Bogie frame

Bogie bolster SIDE BEARING

Center pivot pin TO

Wheel set assembly HELICAL SPRING

Roller bearing assembly TO

Brake beam assembly LOWER SPRING BEAM

Brake head TO

Brake blocks BOLSTER SUSPENSION

SPRING

Brake levers TO

Brake cylinder BOGY FRAME

Primary suspension TO

o Dashpot arrangement PRIMARY SUSPENSION

SPRING

o Spring seating TO

o Problem of oil spillage BEARING HOUSING

o Buffer Height adjustment TO

Secondary suspension BEARING(SPHERICAL

ROLLER BEARING)

o Lower spring beam TO

o Equalizing stay rod AXEL

TO WHEEL

TO TRACK

TO EARTH

N.B- ICF,RCF and BEML are called conventional coaches. BEML are now obsolete. Most popular

coaches are LHB.

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MR(LHB)-SHOP (WORK-MAINTENANCE OF LHB BOGY AND BODY)

Introduction- Till recently, Indian Railways have been transporting passenger traffic

mainly through coaches of ICF design. These coaches are being manufactured at ICF and

RCF. A limited number of these coaches are being manufactured at BEML/Bangalore

also. These type of coaches are having limitations in terms of-

i) Speed potential;

ii) Heavy corrosion;

iii) Poor riding comfort;

iv) Wearing of parts in the under gear;

To overcome these limitations, Indian Railways entered into supply and technology

transfer contracts with M/s. ALSTOM LHB/Germany to initially supply 24 coaches

consisting of 19. AC chair cars, 2 AC Executive Class Chair cars and 3 Generator cum

Brake vans. The bogies for these coaches are manufactured by M/s. FIAT/SIG

Switzerland. These coaches arrived in India and got commissioned in the year 2001 and

put in service . These type of coaches are far superior w.r.t. passenger comfort, safety,

speed, corrosion, maintenance and aesthetics. These coaches are also longer as

compared to ICF design resulting into more carrying capacity. The expected benefits

from these type of coaches are as under:-

i Higher carrying capacity - These coaches are about 2 meters longer than ICF

coaches. With this extra length two additional rows of chairs in chair cars or one

additional bay in sleeper coaches can be accommodated.

ii The weight of LHB coach is lesser as compared to ICF design coaches. LHB

coach can accommodate 72 passengers as compared to 64 in conventional AC III

Tier Coach. Thus giving better pay to tare ratio.

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iii Low corrosion – There will be low corrosion of LHB coaches due to extensive

usage of Stainless Steel and better design and manufacturing techniques.

iv Low Maintenance – Replacement and removal of sub-systems will be required

only after one million kilometers.

v LHB Coaches have aesthetically superior interiors with FRP panels for side wall

and roof. They can be removed easily for maintenance, resist water seepage and

are wear resistant;

vi There are no visible screws inside the passenger compartment.

vii Better passenger comfort: Better Riding Index has been specified as compared to

conventional ICF coaches.

viii LHB coach offers better passenger safety due to:

Use of fire retardant materials for furnishing .

Provision of emergency open able windows.

Vertically interlocked Centre Buffer Couplers.

xi LHB coach offers better passenger amenities due to : More space for pantry;

Individual reading light in chair car;

OBJECTIVES OF THE NEW TECHNOLOGY(LHB)

HIGHER SPEEDS-160 km/h with possibility of upgradation to200 km/h

COMFORTABLE RIDE- ride index of 2.5

LIGHT WEIGHT- 39 tonne for ac chair car

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SHELL- corrosion free

HIGHER AVAILABILITY – 1)reduced maintenance in depot

2) increased periodicity of poh

Method of Repairing

Lifting the Coach Body-

a) On receipt of a coach for Shop Schedule, it must be taken on Lifting

line/

Stripping line where electrical fittings should be stripped and batteries removed.

Furnishings, especially seats and backrests should be inspected thoroughly and

only those that require repairs or attention should be removed.

b) Before lifting a coach, the following components should be removed,

disengaged

or disconnected:-

(i) Wheel sets earthing equipment.

(ii) Speed sensor cover.

(iii) Yaw Dampers.

(iv) Secondary Lateral Damper.

(v) Roll Link from Bolster.

(vi) Wire rope pin from Bolster.

(vii) Hose connection from Bogie to coach.

(viii) Centre pivot security plate.

(ix) Bolster from coach body by means of removing nut & swing nut.

(x) All air brake fittings

(xi) Control arm bottom cover

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(xii) Centre Buffer Couplers etc.

(xiii) CDTS

(xiv) Under slung water tanks & Water Raising Apparatuses (WRA), where

provided.

(xv) Battery box and electrical fittings.

(xvi) AC equipment in AC coaches.

c) Coach body should be lifted off the bogies either by two overhead

electric cranes

of 25 tones capacity each with suitably designed lifting tackles or by four

powered lifting jacks of 15 tones capacity each operated simultaneously by one

control switch. The coach body should be lifted uniformly without jerks and

should remain horizontal during the lifting/ lowering operation. Coach should

not be lifted from any point other than at the lifting pads as shown in figure 2.5.

d) The coach should never be lifted from one end only. If lifted from one

end, the

Centre pivots security plate is likely to suffer damages, body panels are

likely to

get dented near the body bolster. The sealed windows of AC coaches

are also

likely to break.

e) After the coach body is lifted, it should be kept on trestles. The steel

trestles of

the design shown in Figure 2.4 would prove useful for this purpose Lines

should

be protected by scotch blocks with locking arrangement and key should

be kept

with Engineer till the time maintenance work is carried out.

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f) The entire under frame should be cleaned of dust, rust etc. from

underneath by

pneumatic/water jet followed by wire brushing at critical locations and

check for

cracks/damage, corrosion etc. on the under frame members.

g) After carrying out all repairs, the under frame should be painted.

SALIENT FEATURES OF LHB DESIGN COACHES

1) stainless steel used for sidewall, end wall and roof to reduce corrosion

2) light weight shell with inter locked side wall frame and corrugated roof

3) improved ride index

4) fitted with cbc having anticlimbing feature

5) longer coach with higher capacity

6) ergonomically designed seats as per indian an thropometric data

7) large windows with good visibility

8) automatic closing transition doors

9) bi-folding lavatory doors

10) controlled discharge toilets

11) microprocessor controlled air-conditioning with humidity control

12) side walls and ceilings made of glass-fiber reinforced polyester

13) no visible screws in the interior

14) reading lights fitted luggage rack made from Aluminium extrusions

15) entrance area paneling of hpl

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16) toilet compartment made of glass fiber reinforced polyester with corundum surface

17) better insulation against noise and heat

18) floor made of sound absorbing panels with cork core floating on noise damping rubber profiles

19) use of fire retardant materials

20) axle mounted disk brake with wheel slip protection device

21) cartridge taper roller bearings

22) bogies with flexi coil springs, yaw damper, lateral damper and anti-rollbar.

23) silent blocks used in primary and secondary suspensions and stops to cut out noise and jerks

24) increased coach availability due to reduced maintenance

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A(Heat Treatment)-SHOP

A shop basically HEAT TREATMENT Shop, Heat treatment is a group of Industrial and metal

working processes used to alter the physical and chemical properties of a material.

It can be defined as an operation and combination involving heating and cooling of a metal or

alloy in its solid state with the objective of changing the characteristics of a material.

OBJECTIVE :

Heat treatment is employed for the following purposes:

I. To improve machinability.

II. To change grain size.

III. To relieve the internal stresses induced during cold or hot working.

IV. To improve mechanical properties e.g. Hardness, Tensile Strength, Toughness.

DIFFERENT HEAT TREATMENT PROCESS

I. Annealing

II. Normalizing

III. Hardening

IV. Quenching

Heat treatment temperature of Carbon steel

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H(MILL-WRIGHT)-SHOP

Maintain the workability of different mechanical and electrical components of the

different shops of Liluah Workshop as per schedule.

This shop is the main blood vein of the whole workshop. It maintains and services

the different machines and components of the different shops from over-head

cranes, weldings equipments,furnaces,air-

conditioners,vehicles,lifter,compressors,lathes,milling,pressing,drilling machines,

CNC hydraulics to name a few.

This shop is mainly divided into two main component shops:

I. The mechanical mill-wright shop.

II. The electrical mill-wright shop.

Some of the machines that are used in this shop are

I. Lathe machine.

II. Milling machine.

III. Shaping machine.

IV. Hydraulic wrench etc.

Millwrights must be able to read blueprints and schematic drawings to determine

work procedures, to construct foundations for and to assemble, dismantle and

overhaul machinery and equipment, using hand and power tools and to direct

workers engaged in such endeavors. The use of lathes, milling machines and

grinders may be required to make customized parts or repairs. In such case of

work, millwrights are required to move, assemble and install machinery and

equipment such as shafting, precision bearings, gear boxes, motors, mechanical

clutches, conveyors using hoists, pulleys, rollers, trucks.

Mill-wrights are also involved in routine tasks such as lubrication of machinery,

bearing replacement, seal replacement etc.

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Reference :

1. https://en.wikipedia.org/wiki

2. www.rdso.indianrailways.gov.in\

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Signature of the Evaluator Signature of the Trainee