WEST CENTRAL RAILWAY

REGIONAL RAILWAY WELDING INSTITUTE

(RECOGNISED BY RAILWAY BOARD AS WELDING TRAINING CENTRE)

Located at Coach Rehabilitation Workshop, Bhopal (An ISO 9001:2000, ISO 14001:1996 & OHSAS 18000 Certified)

RRWI MAP West

South North

East Coach factory road

Main gate

Colony gate

TTC – Technical Trainning Center

BPS – Bal Bharti Public School

Bhopal Rly. Station PF No.- 1 side

Divisional Railway hospital

Administrative building

Regional Railway Welding Institute

TTC Hostel

Coach rehabilitation Workshop/Bhopal

CRWS Colony

Temple

BPS

RRWI PERFORMANCE ZONE & MODULE WISE YEAR - 2006 – 2014

Year March-April

Railway wise trainees Other Railway Total

Trainee WCR CR NCR WR NWR NER+SECR+NFR+ECR+ECoR

Module - I 438 74 166 41 39 29 787

Module - II 529 324 147 130 61 94 1285

Module - III 74 06 17 08 02 09 116

Module – IV & V 28 06 08 03 03 04 52

Others BHEL - 28 SKILL - 62 Sup. - 42 Helper - 04 CR Total - 136 2376

ZONES AND YEAR WISE YEAR - 2006 – 2014

Year

March-April

Railway wise trainees Other Railway Total

Trainee WCR CR NCR WR NWR NER+SECR+NFR+SCR +ECR +ECoR

2006 - 07 14 02 01 -- -- -- 017

2007 - 08 95 50 74 03 -- -- 222

2008 - 09 150 50 29 35 20 -- 284

2009 - 10 191 90 53 32 28 20 414 2010 - 11 103 63 44 23 15 05 253

2011 - 12 190 70 24 32 05 11 332

2012 - 13 144 56 58 30 16 66 370 2013 - 14 182 29 55 27 24 31 348

Total 1069 410 338 182 108 133 2240

Others BHEL - 28 SKILL - 62 Sup. - 42 Helper -04 CR Total - 136 2376

ZONES AND YEAR WISE YEAR - 2006 – 2014

Year

March-April

Railway wise trainees Other Railway Total

Trainee WCR CR NCR WR NWR NER+SECR+NFR+ECR+ECoR

2006 - 14 1069 410 338 182 108 133 2240

Others BHEL - 28 SKILL - 62 Sup. - 42 Helper - 04 CR Total - 136 2376

WCR - 1090

CR - 410

NCR - 338

WR -182

NWR - 108 Other Rly. - 133

Non Rly. BHEL - 28Other welding - 104

RRWI PERFORMANCE – 2006 -14

ZONE & MODULE WISE YEAR - 2006 – 2014

Year

March-April

Railway wise trainees Other Railway Total

Trainee WCR CR NCR WR NWR NER+SECR+NFR+ECR+ECoR

Module - I 438 74 166 41 39 29 787

Module - II 529 324 147 130 61 94 1285

Module - III 74 06 17 08 02 09 116

Module – IV & V 28 06 08 03 03 04 52

Others BHEL - 28 SKILL - 62 Sup. - 42 Helper - 04 CR Total - 136 2376

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Module - I Module - II Module - III Module - IV & V

Other Welding

Non Rly.

OtherRly.

NWR

WR

NCR

CR

WCR

PREFACE

Welding Technology has emerged as an important and critical process of manufacturing and repair in Railway Workshop. The biggest challenge to Railway Workshop is to sustain quality of welding in critical area of Rolling Stock specially of under frame and under slung equipment. The quality of welding is function of Welders skill and welding equipments.

Indian Railway is deploying approximately 20,000 Welders and majority of them are promoted from Khalasies i.e. Group ‘D’ staff. Thus emphasizing the need of proper training to Railway staff who are choosing Welding Trade as their profession.

SRSF Committee (Khanna Committee Part-I) has also recommended at Para 5.10 for competency-based training for work centers such as TXR depots, ROH depots & WORKSHOP etc.

Railway Board vide their letter No.2000/M(M&P)1063/II dated 13.04.01 have appointed a SAG level committee to assess feasibility & desirability of setting up of Training Centers to improve welding quality among Railway Welders. This committee has studied in detail the requirement of welding Training to Railway staff and has submitted exhaustive report for setting up of Regional railway Welding Institute (RRWI) at following 4 locations :-

1. RCF Kapurthala. 2. DLW Varansi 3. ICF/Chennai. 4. CRWS/BPL

These Training Institutes cater the training requirement of All Indian Railway Welders. This Training Institute provides training for beginners, Refreshers, Pre-promotional and special training as and when required. Keeping in view, the different training need of Staff, five modules of training have been prepared.

Unlike POH workshops, Coach Repair Workshop, Bhopal is a unique Workshop for the rehabilitation of coaches of INDIAN RAILWAY. Its activities are focused towards corrosion repair & total rehabilitation of body, under frame members. This involves modern gas/plasma cutting & welding of structural member followed by refurnishing of full coach once in the life. The workshop has ISO-9001: 2000 for quality & its management system, ISO-

14001 for its environment management system & ISO-18001 for occupational health & safety.

We are using all modern techniques in the repair of coaches like CO2 welding, TIG welding, plasma cutting, grit blasting of coaches & its components etc. We also have a MOU with BHEL, Bhopal for demonstration of latest welding & cutting technology to our trainee welders.

The center has number of qualified trainers, workshop, modern teaching-aid equipments, Class rooms, auditorium, and welding laboratory with ‘X’--rays facility, and model room for accomplishing its aim and objectives. The center is doing the job of training since last eight years and with the co-operation and ideas / suggestions of its users will continue on the path of progress and prosperity of INDIAN RAILWAY.

MISSION STATEMENT

“TO DEVELOP THE POSITIVE ATTITUDE,

KNOWLEDGE, SKILL & WORKMANSHIP OF

RAILKWAY WELDERS WHICH IMPROVES THE

QUALITY & GOOD WILL OF ORGANIZATIONAND

ALSO MOTIVATE THEM FOR INCREASING THE

RODUCTIVITY & IMPROVEMENTS IN THE

PERFORMANCE OF THE INDIAN RAILWAYS.”

INTRODUCTION REGIONAL RAILWAY WELDING INSTITUE, Bhopal of west central

railway is situated in the city of lakes of M.P It is located about a distance of 03 KMs from the Bhopal Railway station & attached with Coach Rehabilitation Workshop.

RRWI was established in the year Jan.2007, to cater the training need of the welding supervisors & welders of the mechanical department.

Special courses as well need base training programs to meet the training need of the Indian Railway welders are also conducted at RRWI/Bhopal. Training centre has over the year developed excellent relationship with the division and workshops of Indian Railway in its jurisdiction.

METHODOLOGY OF TEACHING Lectures, group discussions, audio-visuals, demonstrations & practical

facility of welding in all position by SMAW,GMAW, Plasma cutting, TIG welding and display of charts & board. All presentations on power point and display charts are bilanguage i.e. Hindi & English. Welders visit to BHEl, Bhopal & Industrial area Govinpura, to see latest welding & cutting processes in fabrication industries. Welders job evaluations being done in weld Laboratory. The feedbacks of trainees are being taken from their shop incharge/SSE and suggestion collected from trainees & customers to increase productivity & quality in welding.

RRWI WELDING TRAINING MODULES

Module Description of Modules Duration of the Course in weeks

Theory Hrs.

Practical Hrs. Remarks

I

Basic welding training for beginners (Promotees from khalasis and skilled grade III direct recruits) This will give them enough knowledge and confidence about welding for their day-to-day work.

04 45 135

II On the job continuous improvement training (Refresher course) 03 45 90

III Need based training on specific topics like Weld Distortion, Metallurgy and weld joints design.

02 45 45

IV Training for welding supervisor, welding inspectors and C&M staff in service.

02 45 45

V Training for newly recruited welding supervisor (Direct recruits). 02 45 45

VI Requirements for training of Training Officers, welding instructors in welding institutions.

This Modules conduct by nodal agency DLW Varanasi

VII Training for Junior and Senior scale officers of mechanical branch including CMTS and ACMT’s

RRWI WELDING TRAINING MODULES MODULE-I

BASIC WELDING TRAINING FOR BEGINNERS

This is basically for those staff that gets into the welding trade on promotion from Group-D to Gr.III and Skilled Gr.III direct recruited. This will give them enough knowledge and confidence about welding for their day-to-day work.

Duration of the Course : 4 Weeks Theory : 45 hrs. Practical : 135 hrs.

MODULE-II ON THE JOB CONTINUOUS IMPROVEMENT TRAINING FOR REFRESHER COURSE

This module has been planned for Welders with one or two year experience in repair shop. This will refresh their knowledge and up-grade their skill. It shall be mandatory in nature for promotion from Group-III to Group-II and Group-II to Group-I.

Duration of course : 3 Weeks Theory : 45 hrs. Practical : 90 hrs.

MODULE-III NEED BASED TRAINING ON SPECIFIC TOPICS LIKE WELD DISTORTION, WELD

JOINT DESIGN AND THEIR METALLURGY

Duration of course : 2 Weeks Theory : 45 hrs. Practical : 45 hrs.

MODULE-IV TRAINING FOR WELDING SUPERVISORS, WELDING INSPECTORS

AND C&M STAFF

This module is designed for Welding Supervisors; Inspectors & C&M staff to up-grade their knowledge.

Duration of course : 2 Weeks Theory : 45 hrs. Practical : 45 hrs.

MODULE-V TRAINING FOR NEWLY RECRUITED SUPERVISORS (JE-II & SE)

All trainee supervisors in Welding Trade will need to undergo this module. All direct recruits supervisors, JEs shall under go in Module-I & II during 1st year and Module-IV during 2nd year. Duration of course : 2 Weeks Theory : 45 hrs. Practical : 45 hrs.

MAJOR AREAS COVERED AT RRWI/BHOPAL

p Manual metal arc welding

p Gas metal arc welding (MIG,MAG,FCAW & TIG)

p Welding joints ,Position Symbols & terminology

p Welding defects & its remedies

p Inspection & testing of weldments

p Metal cutting processes

p Weld quality & distortion control

p Modern welding & SS welding

p Practices on skill up gradation of welders

p Knowledge of weld consumables

RRWI is equipped with the following modern training audio-visual aids. All presentation developed by teaching staff on power point are bi-language i.e. Hindi & English which includes text & diagrams.

LCD PROJECTOR DIGITAL CAMERA 21” MONITOR

OVER HEAD

PROJECTORS

SPIRAL BINDING MACHINE

VCD PLAYER

WHITE BOARDS DIGITAL PHOTOCOPIER PERSONAL

COMPUTERS

COMBI BOARDS TRANSPARENCIES (DEVELOPED BY

TEACHING STAFF OF RAINING CENTRE).

DOT MATRIX PRINTER

COLOUR INK JET PRINTER

TRAINING AIDS

WELDING TRAINING INFRASTRUCTURE

TRAINING FACILITIES

• MMAW Welding plants transformers – 05 Nos

• MMAW Welding plants rectifiers – 05 Nos

• MIG/MAG Welding plants – 05 Nos

• TIG welding plant – 01 No.s

• Inverter base Pulse MIG welding – 01 No.s

• Plasma Cutting Machine – 01 No.s

TESTING FACILITIES

• Impact testing M/C

• Universal testing machine

• Portable radiographic x ray unit

ASSESSMENT FACILITIES

• Microscopes

• Micro polisher

• Moisture tester

• Magnetic particle inspection

• Dye penetrant Kit

• Tong tester

• Weld gauges

WELDER GRADING SYSTEM

• Category ‘A’ -- 80% and above

-- Eligible for critical & safety welding items

• Category ‘B’ -- 65% to 79%

-- Eligible for critical & safety welding items

• Category ‘C’ -- 50% to 64%

-- NOT Eligible for critical & safety welding items

only suitable for rough & tack welding

• Category ‘D’ -- below 50% (Fail)

-- NOT Eligible for welding and rebook in training

Within three month

MODEL ROOM Model room is equipped with the various boards, charts & welding and

cutting items for demonstration of trainees.

LIBRARY

A Library which having a collection of 1100 books, covering a wide range of Engineering, Management, Railway Engineering subject, & a Hindi section with 750 Books on literature are available for the benefit for the trainees. Varies technical pamphlets and manuals are also available.

äMESSING FACILITY

Managed by contractor on contract basis

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Hostel is provided with TV and reading room.

Newspaper in Hindi & English and magazines are also available.

SPORT FACILITY:

Excellent facilities for outdoors and indoors are also available.

S.No. OUTDOOR GAMES INDOOR GAMES

1. VOLLEY BALL TABLE TENNIS

2. CRICKET CAROM

3. BADMINTON CHESS

ENTERTAINMENTS AVAILABLE

hMEDICAL ASSISTANCE AVAILABLE

Medical assistance is available 24 hours as division hospital is situated at 600 meters distance from the training Centre.

Emergency Tel. No. 7520 (for Doctor on duty)

DESIGN.

RLY. OFFICE

P&T OFFICE MOBILE

CWM 7400 0755 - 2742785 9752416450

Dy.CME 7402 0755 - 2743863 9752416452

(Trg. Officer/ WM(M) 7408 0755 - 2746794 9752416451

CI/RRWI 7473 0755 - 2746068 9752416182

Hostel 7928 0755 - 2476681 ---

Fax No. 0755 - 2743863, 0755 - 2747290

WCR Web site www.wcr.indianrailways.gov.in

E – Mail crwsbpl@gmail.com,

crwsbpl@rediffmail.com prageshnimbalkar@gmail.com

maliksaketbpl@yahoo.com

COMMUNICATION

REGIONAL RAILWAY WELDING INSTITUTE ( Recognised by Railway Board as Welding Training Centre)

COACH REHABILITATION WORKSHOP, BHOPAL TRAINING CALENDAR WELDING COURSES FOR WCR, CR, NCR, WR & NWR – YEAR - 2014

Welder gradation certificate course approved by Railway Board

S. No.

Month

MODULE – I Training For New welders

Starting day:- First Monday of Every month

Duration - 04 Weeks Quota - 02 trainees

/Course/Railway unit No course in Oct.-2014

MODULE – II

Training for Experienced welder (Refresher Course)

Starting day :- First Monday of every month

Duration - 03 Weeks Quota - 02 trainees /Course/

Railway unit *No course in Oct.-2014

MODULE – III

Need based training for welders after completion of Module I /II

training in RRWI Duration - 02 Weeks

*Course in Oct.-2014 only

MODULE – IV & V

Training for Mechanical supervisors in field of welding

Duration - 02 Weeks *Course in Oct.-2014 only

For more details please contact

CI/RRWI Rly. – 016 – 7473M – 09752416182

Training Officer-WM(Mech.)M – 09752416451Rly. – 016 - 7408

P &T - 0755 - 2746794Dy.CME(MR)/CRWS/BPL

M – 09752416452Rly. – 016 – 7402

P &T - 0755 – 2743863OFFICE FAX

0755 – 27438630755 – 2747290WCR Web site

www.wcr.indianrailways.gov.inE – Mail

crwsbpl@gmail.comcrwsbpl@rediffmail.com

prageshnimbalkar@gmail.com

COURSE FROM TO COURSE FROM TO

Welders can be booked for special training in MIG/MAG/Co2 , Plasma cutting and Stainless steel welding

Experienced, newly recruited &promoted supervisor may

be booked

01 Jan. – 14 71 06/01/2014 01/02/2014 76 06/01/2014 25/01/2014 02 Feb. – 14 72 03/02/2014 01/03/2014 77 03/02/2014 22/02/2014 03 March-14 73 03/03/2014 29/03/2014 78 03/03/2014 22/03/2014 04 April – 14 74 07/04/2014 03/05/2014 79 07/04/2014 26/04/2014 05 May – 14 75 05/05/2014 31/05/2014 80 05/05/2014 24/05/2014 06 June – 14 76 02/06/2014 28/06/2014 81 02/06/2014 21/06/2014 07 July – 14 77 07/07/2014 02/08/2014 82 07/07/2014 26/07/2014 08 Aug. – 14 78 04/08/2014 30/08/2014 83 04/08/2014 23/08/2014 09 Sep. – 14 79 01/09/2014 27/09/2014 84 01/09/2014 20/09/2014 10 Nov. – 14 80 03/11/2014 29/11/2014 85 03/11/2014 22/10/2014 11 Dec. – 14 81 01/12/2014 27/12/2014 86 01/12/2014 20/12/2014 COURSE FROM TO COURSE FROM TO

12 Oct. – 14

MODULE – III , IV & V

23 06/10/2014 18/10/2014 08 06/10/2014 18/10/2014

Ø Nomination of welders can be done for entire year well in advance for full utilization of courses. Welders will report to institute along with dangri & safety shoes and may not avail leave during training period.

Ø As per Railway Board guidelines, welders of Module – II to be evaluated on the basis of theory and practical test and awarded Grade A, B, C, & D Grade “A” for 80% and above marks -- (‘A’ Grade welders are eligible to weld all critical welding joints.) Grade “B” for 65% to 79% marks -- (‘B’ Grade welders are eligible to weld all critical welding joints.) Grade “C” for 50% to 64% marks -- (‘C’ Grade welders can be authorized in tack welding and gas cutting work only) Grade “D” for Below 50% -- (‘D’ Grade welders not allowed for welding and should undergo training again till found suitable for welding job.)

Ø New welder after getting training in Module – I must continue practice to develop their proficiency in welding jobs. Ø The hostel accommodation will be provided to trainees during training period, but mess charges will be borne by individuals. Ø Special courses, if required can be organised with prior approval of CRWS/WCR/Bhopal. Ø Welders may be rebooked in refresher course only after completion of 05 years and those due for retirement within 01 year and suffering from chronic

disease may not be deputed.

Approved by CWM/CRWS/Bhopal

INSTRUCTIONS FOR THE GUIDANCE OF THE TRAINEES ATTENDING COURSES AT RRWI/BPL

1. The working hours of this training centre are from 8.30 hrs. to 12.15 hrs. and

13.00 hrs. to 16.30 hrs. Except on Sunday & holidays.

2. No leave will be granted to trainees during the period of training except in

emergency cases.

3. Hostel accommodation will be provided to all trainees attending training at

RRWI/BPL on first cum first served basis to the extent possible.

4. This training centre will provide Pillow, Blanket, Bed sheet and Mosquito

net/Jet machine to trainees during their stay in hostel.

5. The mess facility on contract basis for trainees available. Trainee shall

deposit an amount of Rs. 1500/1000 on joining, which will be adjusted against

dues latter on.

6. No trainees will be permitted to leave the hostel premises without permission,

except in emergency cases.

7. All trainees have to maintain upmost discipline in the training centre &

hostel. Smoking, tobacco-chewing, pan-spitting, Drinking is sticky prohibited

in RRWI & Hostel, violation of rule is liable to sent back with the

termination of training.

8. Visitors are not allowed to stay in the hostel during night hours without

permission from Training officer/ Chief Instructor except in emergency

cases.

9. Trainees attending the course should be well dressed with safety shoes and

welders should bring their Dangri /Boiler suit for practical training.

10. All the trainees required to clear their dues from library, mess & deposited

their helmet to this office, before reliving.

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