DELHI METRO RAIL CORPORATION Ltd.(A Joint Venture of Govt. of India and Govt. of Delhi)

26th MAY to 6th of JULY 2016

SUBMITTED BY MOHAMMAD AHMAD

13/IME/029

Under the Supervision ofMr. AMIT GIRI

Training In-chargeYamuna Bank Depot,

DMRC,New Delhi.

SUMMER TRAINING PROJECT REPORT

• I Express my sincere gratitude to DELHI METRO RAIL CORPORATION (A Joint Venture of Govt. of india and Govt. of Delhi) to Participate and provide us with the technical knowledge in the Rolling Stock Department of (Yamuna bank Depot) Delhi Metro Rail Corporation.• At the outset,I would like to express my immense gratitude to my training

guide ,Mr.Amit Giri, guiding me right from the inception till the Suceessful completion of the Training.• I am falling short of word for expressing my feeling of gratitude toward him for

extending their valuable guidance, through critical Receives of project and the report and above all the moral support he had provided me with all stages of this Training.• At last I Would be Thankful to our HOD Sir and Faculty Members to give the the

opportunity to do the training and support at everystep.

ACKNOWLEDGEMENT

CONTENTS • Introduction • Rolling Stock overview• Car Body• Bogie and Suspension• Gangway and Coupler• Brake and Pneumatic system• Heating, Ventilation and Air-Conditioning (HVAC)• Doors

INTRODUCTION• Planning for the metro Started in 1984,when the Delhi Development Authority and the

Urban Arts Commission Came up with a proposal for developing a multi-modal transport system for the city.The Government of India and the Government of Delhi jointly set up the Delhi Metro Rail Corporation(DMRC) in 1995.Construction Started in 1998,and

• The first Section, on the Red Line, opened in 2002, • Followed by Yellow Line in 2004,• The Blue Line in 2005,its branch line in 2009,• The Green and Violet Lines in 2010 and• The Delhi Airport Metro Express in 2011

• A Company under the name DMRC was Registered on 30.05.1995 under the companies act for construction and operation of the metro project. The Government of India and the Government of Delhi jointly set up a company called the Delhi Metro Rail Corporation (DMRC) on March 5,1995 with E.Sreedharan as the Managing Director. It started functioning in November ,1997.It appointed General Consultant in August,1998 to assist them for implementation of the project.It is having 142 stations in the Rail Corridor (underground).It has a Combination of Elevated ,at-grade and underground lines and uses both broad gauge and standard gauge rolling stock.• The Delhi Metro Rail Corporation has Been Certified by the United Nations as the

first Metro Rail and Rail-based System in the world to get “carbon credits for reducing greenhouse gas emissions”.• Delhi Metro brought a revolutionary change in the city transport. It has also reduced

travel time. Also the pollution level is reduced to about 50%.A large number of commuters are having lot of Convenience in reaching their desired destination in the required time.

The network comprising six lines with 140 metro stations.

Line Stations Length

(km)Terminals

Red Line 21 25.15 Dilshad Garden - Rithala

Yellow Line 34 44.65 Jahangir Puri - Huda city centre

Blue Line 44

6

50

6.25

Noida city centre/Vaishali - Dwarka Sec21

Green Line 5 18.46 Inderlok / Kirti Nagar - Mundka

Violet Line 15 20.04 Central Secretariat - Badarpur

Airport Express 6 22.70 New Delhi - Dwarka

FINANCE AND FUNDING From Govt. of India and Govt. of Delhi contributes equal shares. trough soft loan from

Japan bank due for international cooperation.

REVENUE AND PROFITS Revenue from advertisement, property development and leasing out trains station for

film shoots.

NEED OF DELHI METRO As astounding it may sound Delhi have more vehicles than Mumbai, Kolkata and

Chennai taken together. The number is somewhere close to 40lakhs. Estimates are pitching Delhi’s population close to 22.5 million by 2021.All this Would be incomplete if population was not given a mention,64% of population in Delhi can be credited to motor vehicles out of which 70% are two wheelers.

Dr.E.Sreedharan handed over charge as MD,DMRC to Shri Mangu Singh on 31December,2011.

INTRODUCTION ABOUT YAMUNA BANK DEPOT• Yamuna Depot station is a large train maintance depot and an import interchange

station as well located on the Blue line of Delhi Metro.• Date of Commissioning of the Depot: 6th may 2005• Total Number Train Holding in Depot: 36 trains• Total Number of RS.2 Trains: 30 trains {4No’s(8car)+26No’s(6car)}• Total Number of RS.1 Trains :06 trains {6No’s (8car)}• Total car Holding:236 car

.

.

SECURITY• Central Industrial Security Force(CISF)• Closed Circuit Cameras • Dog Squads • Emergency Communication b/w Passengers and Driver

ROLLING STOCK• The first wave of Rolling stock was manufactured by a consortium of companies comprising

ROTEM, Mitsubishi Corporation and Mitsubishi Electric Corporation. Initial sets were built by ROTEM in South Korea, with later examples Completed in India by public sector undertaking Bharat Earth Movers Limited(BEML).BEML is also responsible for the manufacturing coaches under technology transfer agreement. The air-conditioned trains consist of four 3.2m wide ,stainless steel, lightweight ,although six and eight coaches is possible. The trains have automatic doors, secondary air suspension and brakes controlled by microprocessor. Delhi Metro has fleet of 280 coaches, which DMRC Runs as 70 trains everyday. Each train can accommodate about 1,500 people,240 seated. Maximum speed is 80km/h (50mph),with a 20-second dwell time at stations. Train depots are located at Khyber Pass,Najafgarh, Shastri Park,Mundaka,Sarita Vihar and Yamuna Bank.

• In May 2011, BEML received a contract worth Rs.9.2bn($205m) from DMRC to supply 136 intermediate metro cars. The delivery is expected to be Completed by December 2013.In March 2008 Bombardier Transportation announced an 87m($137m) contract for 84 MOVIA metro cars,a follow- on to an order for 340 placed July 2007.The new Vehicles are being deployed as part of phase II Expansion. In September 2011,Bombardier received a $120m order for 76 additional MOVIA Metro Cars.

• A Phase I board gauge train, supplied by Hyundai Rotem-BEML(RS-1).• A Phase II board gauge train, supplied by Bombardier(RS-2).• The Metro Rolling Stock of two different gauges. Phase I lines use 1,676mm

(5.499ft) broad gauge rolling stock, while three Phase II Lines use 1,435mm (4,708 ft)standard gauge rolling stock.• Broad gauge • The broad Gauge rolling stock is manufactured by two major suppliers Hyundai

Rotem,Mitsubishi Corporation and MELCO.The coaches were initially built in South Korea by ROTEM.• Standerd gauge The initial trains were made in Germany and Sweden, the remainder will be built at

Bombardier’s factory in Savli,near Vadodara. The coaches posses several improved features like Closed Circuit Television(CCTV) Cameras,charging points in all coaches for cell phones and laptops, improved air conditioning to provide a temperature of 25 degree Celsius even in packed conditions and heaters for Winter.

RS-2 TRAIN OVERVIEW:

• TRAIN FORMATION:• One train set consists of 4/6/8 cars. Three types of cars (DT,T and M) are used to form a train

set. At each end is a “DT” car which is a trailer car with driver’s cab and pantograph. The other type is an “M” car, which is a motor car without pantograph and “T” car with pantograph.

-4 carThe 4-car trains consist of driving trailer car with pantograph (DT) and motor car (M), in the following configuration DT-M + M-DT.

- 6 car The 6 car train consists of driver trailer car with pantograph (DT), motor car (M) and

trailer car with pantograph (T), in the following configuration DT-M + T-M + M-DT.

- 8 car The 6 car train consists of driver trailer car with pantograph (DT), motor car (M) and trailer car with pantograph (T), in the following configuration DT-M + T-M + T-M + M-DT.

• SALIENT FEATURES:• Broad gauge (1.676 metre )• 25 KV Supply Voltage System• Light weight stainless steel structure• Three phase A.C. induction motor• Fail safe braking system with regenerative braking.

Car Body:RS-2 trains have three different car bodies, one for each type of car in the train set.• DT car body• M car body• T car body The function of car body shell is to carry and protect the passengers, staff and various subsystems

of the train. The car body shell distributes the accelerating and braking forces generated by the bogie.

• FUNCTIONS OF CAR BODY:• To carry passengers and the payload.• To protect the passengers and the payload against external forces.• To protect the passengers and the payload against moisture, heat, cold, vibration and noise etc.• To support other subsystems.• To transfer tensile and compressive loads between cars.

NOMNECLATURE OF CAR BODY

PROMINENT DIMENSIONS AND TOLERENCES:1) Height of the coupler center from the Top Of Rail (TOR)

800+/-5%

2) Car body length (Including coupler length) DT : 22,600 mmM : 22,240 mmT : 22,240 mm

3) Maximum width of body 3,180 mm

4) Tare weight DT car : 44.5 tonM car : 43 tonT car : 42 ton

5) Dropped down panto height 25kv from TOR at Car Centre Line

4048 mm

6) Height of floor from TOR 1,130 mm

MAIN STRUCTURAL COMPONENTS:The car body is built up with a set of modules:

Body side module. End walls. Cab module and

Driver’s end wall. Roof module. Under frame module

Bogie and Suspension:

Bogie is a mechanical framework having arrangement to carry wheel sets, traction motors, gears, brakes and suspension equipment.

The main function of the bogie is to:-• Support the car body.• Allow relative movement between car body and bogie.• Ensure stable running.• Ensure adequate ride comfort.

BOGIE FRAME:• There are two frame types, Trailer an Power bogie frame. The bogie frames

are formed from steel plate fabrication with small inset steel castings. Castings are used for the frame end castings, radial arm mounting lugs, brake hangers and motor mounts.

Wheel and axleWheel • The wheels are of forged mono bloc steel• Wheel material – R8T• Wheel diameter – 860 mm with 40 mm

wear allowance• Wheel back to back dimension – 1600/+2,-

1 mm• The distance between axle centre lines, 2.5

m

Axle• The axle has machined seats for the

wheels and axle boxes.• There is also a machined seat on the drive

axle to accommodate the gear, which is shrunk onto the axle. • Because of the integral gearbox fitted to

the motor bogie, motor and trailer axles are not interchangeable. All axles are inspected through ultrasound testing (UST) and magnetic particle inspection (MPI).

Gangway and coupler:

• The gangway, comprising two gangway halves, is the flexible part of the train, allowing relative movements between the cars and offering passengers a secure and comfortable passageway.• All intermediate car ends are

connected via intercommunication gangways to allow free and safe passenger movement between cars, including when the train is in motion. Passengers can stand within the gangway with a high degree of safety and comfort. Furthermore, the gangway design ensures

Coupler • Automatic coupler • The main task of the automatic

coupler is to allow mechanical and pneumatic coupling. These are fitted at the outer ends of a train set and are links between train units.

• Semi-permanent couplers• These couplers are used

between the cars within a 2-car unit, which are joined together with a separate muff fixed with screws and nuts. The couplers mechanically connect one car to another and form a rigid and slack free connection.

• Intermediate Automatic coupler

• The main task of the coupler is to allow mechanical coupling between the cars in the train set and to transmit compressive and tractive loads.

Brake and pneumatic system:

• The brake system is a combination of mechanical and electronic devices operated by compressed air, arranged in a system and controlled manually, pneumatically or electronically by means of which the motion of cars is retarded or stopped.• The brake system includes-• Friction brake• Electro Dynamic (ED) brake• Parking brake• Holding brake• Wheel slide protection (WSP)

Air Supply System

The air supply system supplies compressed air to consumers, such as the brake system, secondary suspension and pantographs.

The main air supply unit is the subsystem of train and is fitted in the underframe of each M-car which supplies compressed air to the complete train via the Main Reservoir Pipe (MRP).

Air supply unit basically consists of:• Compressor• Air treatment • Filter units

Heating, Ventilation and Air-Conditioning (HVAC):

• The Heating, Ventilation and Air-Conditioning (HVAC) system is used for heating, cooling and ventilation of the saloon area as well as cab area.• The primary function of the HVAC unit is to achieve and maintain acceptable indoor

climate and air quality for the passengers.• Secondary functions are:• To protect the passengers from smoke in case of smoke outside the train, and • To secure the CO2 levels inside the train if auxiliary power fails.

Major components:

Doors A door in a train is a panel or barrier, usually hinged or sliding, that is used to cover an

opening in a train. Exterior doors are doorways that allow entrance or exit from a train.There are three types of exterior doors available in RS2:• Cab or driver’s door• Passenger door• Detrainment door

• Cab doors• The function of the cab or driver’s door is to provide access to the cab for the driver.

Only DT car is equipped with two cab doors.

• Passenger door• The function of the passenger door is to prevent passengers from entering or leaving the

train.• Each car has 8 passenger doors• Each door consists of two door leaves• Sliding externally on the car body wall• Electrically operated

• Detrainment door• The function of the detrainment door is to provide evacuation of passengers and crew to

track in case of emergency.• When detrainment door opens it becomes an emergency ramp from cab floor level down

to track level.• The detrainment door is bolted into the cab structure.• The door is located in the front of the cab.• Free opening width 750 mm.• Free opening height 1900 mm.

Thank you for

your Attention