NORTH EAST RAILWAY GORAKHPUR (U.P)

INDUSTRIAL TRAINING REPORT 2014-15

GREATER NOIDA, G.B.NAGAR, U.P.

SUBMITTED BY-

NAME-PIYUSH KUMAR TIWARI

ENROLLMENT- 1101201022

BRANCH-MECHANICAL ENG.

ACKNOWLEDGEMENT

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. ANIRUDH SHINGH who

provided me every help and removed my

doubts about the particular shop.

NAME –PIYUSH KUMAR TIWARI

DATE-17/07/2014

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

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

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

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

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.

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

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.

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.

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.

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 .

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

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.

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.

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.

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

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.

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.

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

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

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.

HEAT TREATMENT SHOP

Heat treatment is the process of heating and cooling of

a material to change its physical and mechanical

properties without changing the original shape and

size. Heat treatment of steel is often associated with

increasing its strength, but can also be used to improve

machinability, formability, restoring ductility, etc. Basic

heat treatment process for steels are described in the

following subsections.

HEAT TREATMENT

DIFFERENT TYPES OF HEAT TREATMENT PROCESS

1. Hardening.

2. Tempering.

3. Austempring.

4. Martempring.

5. Annealing.

6. Stress relieving.

7. Spheroid zing.

8. Normalizing

9. Case hardening.

10. Cyaniding.

11. Flame hardening.

12. Induction hardening.

13. Nitriding.

IRON CARBON DIAGRAM-

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

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.

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.

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.

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.

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.

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

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

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.

OVER HEAD CRANE

BELT CONVEYER

SMALL INDUSTRIAL TRUCKS

REFERENCES

1. www.wikipedia.org

2. www.slideshare.com

3. V.B. Bhandari.

4. Google images.

5. John Wiley & sons.

6.Nptel lectures.

7.Ghosh& Malik.

8.Indianrailway.org.in