CARRIAGE AND WAGON WORKSHOP

LILUAH, HOWRAH (WEST BENGAL)

Submitted on completion of Industrial Training at C & W, Liluah

(11th March 2024 to 23rd March 2024)

Submitted by-
Swati Kumari
B. TECH, Mechanical Engineering (2021-2025)
Ramkrishna Mahato Government Engineering College, Purulia
 ACKNOWLEDGEMENT
I take this opportunity my sincere thanks and deep gratitude to all these people
who extended their whole hearted co-operation and helped me in completing
this project successfully.

First of all I would like to thanks all the S.S.E. and J.E. of the all the sections for
creating opportunities to undertake me in this esteemed organization. Special
thanks to the entire department for all the help and guidance extended to me
by them in every stage during my training. His inspiring suggestions and timely
guidance enabled me to perceive the various aspects of the project in the new
light.

In all I found a congenial work environment in CARRIAGE AND WAGON

WORKSHOP, LILUAH and this completion of the project will mark a new
beginning for me in the coming days.

THANK YOU
 CONTENTS
SL.NO SHOP

1. A

2. G

3. C

4. M

5. MR/L-BAY

6. H

7. MR/ABK

8. MR/LHB

9. K

10. L

11. TOOL ROOM

12. BTC
 A-SHOP
At the A-Workshop, precision and efficiency are paramount. Here, locomotives undergo
meticulous inspections, repairs, and refurbishments to ensure they remain in optimal
condition for safe and reliable operations. From routine maintenance tasks to complex
overhauls, every aspect of railway engineering is handled with utmost care and expertise.

Electric furnace
An electric furnace is a type of furnace that uses electricity to generate heat for various
industrial processes such as melting metals, heating or producing ceramics. Unlike
traditional furnaces that rely on combustion of fuel like coal, gas, or oil. Electric furnaces
utilize electrical resistances heating elements to generate heat.

In an electric furnace, electrical current passes through resistive elements typically made of
materials such as nichrome, which offer high resistance to the flow of electricity. As the
current flows through these elements, they heat up due to resistance, thus generating
intense heat within the furnace chamber.
The mechanism of an electric furnace revolves around the principle of electrical resistance
heating. Here's a breakdown of how it works:
Heating Element:The core component of an electric furnace is the heating element. These
are typically made of materials with high electrical resistance, such as nichrome (an alloy of
nickel and chromium). When an electric current flows through these resistive elements, they
heat up due to Power Supply: The electric furnace is connected to a power supply, typically
an electrical grid or a dedicated power source. The power supply delivers electrical energy to
the furnace, which is then converted into heat by the heating elements.
Control System: Electric furnaces are equipped with control systems that regulate the flow
of electricity to the heating elements. This control system allows for precise adjustment of
the temperature within the furnace, ensuring that it remains at the desired level for the
specific application.
Thermostat:Many electric furnaces also incorporate thermostats to monitor and control the
temperature inside the furnace chamber. The thermostat detects the temperature and
signals the control system to adjust the flow of electricity to the heating elements
accordingly, maintaining the desired temperature level.
Insulation:To maximize efficiency and minimize heat loss, electric furnaces are often
insulated. This insulation helps to retain the heat generated by the heating elements within
the furnace chamber, ensuring that it is effectively utilized for the intended purpose, such as
melting metals or heat treating materials.
Furnace Chamber:The furnace chamber is the enclosed space where the heating
elements are located and where the heating process takes place. It is designed to withstand
high temperatures and may be lined with refractory materials to protect against heat
damage.
Electric furnaces could be used for various purposes such as:
Heat Treatment:Electric furnaces can be employed for heat treating railway components
like axles, wheels, and springs to improve their mechanical properties and durability.
Welding And Brazing:Electric furnaces equipped with induction heating coils or
resistance heating elements can be used for localized heating during welding or brazing
processes to join metal components.
Metal Melting And Casting:In certain cases, electric furnaces may be used for melting
and casting metal alloys to produce specialized railway components or spare parts.
Annealing: Electric furnaces are commonly used for annealing processes to soften metal
components, making them easier to machine or reshape.
Forge Heating:In railway workshops involved in manufacturing or repair of large metal
components, electric furnaces may be used for forge heating to prepare materials for forging
operations.
 HYDRAULIC VERTICAL PRESS MACHINE

A hydraulic vertical press machine is a type of industrial equipment used for various pressing
and forming operations, typically in metalworking, fabrication, and manufacturing processes.
This machine utilizes hydraulic pressure to exert force vertically onto the workpieces, which
is often placed between two platens or dies. The vertical orientation of the press allows for
efficient loading and unloading of workpieces from the top.
The Liluah Workshop has a hydraulic vertical press machine; it would likely be used for tasks
such as:
Metal Forming:Pressing and forming metal components used in railway infrastructure or
rolling stock, such as brackets, fittings, and structural elements.
Assembly Operations: Press-fitting or pressing components together during assembly
processes, ensuring secure and precise connections.
Repair and Maintenance:Straightening or reshaping metal parts that have been
damaged or distorted, such as rail tracks, axles, or chassis components.
Fabrication:Manufacturing new components or parts for railway equipment, such as
brackets, couplings, or mounting plates.
Component Testing:Applying controlled pressure to test the strength and integrity of
components, ensuring they meet safety and quality standards.
Hydraulic vertical press machines are versatile tools that can handle a wide range of
pressing, forming, and assembly tasks. They provide high force capabilities and precise
control, making them valuable assets in industrial settings like railway workshops.
 OVERHOULED OVER HEAD TANK

An overhauled overhead tank typically refers to a water storage tank that has undergone a
comprehensive maintenance process to ensure its optimal functioning and structural
integrity. Overhauling an overhead tank is essential to address any issues related to wear
and tear, corrosion, leaks, or mechanical failures, thereby extending its lifespan and
maintaining water quality standards.
Initial Assessment:Conduct a comprehensive inspection of the overhead tank to assess
its condition. Look for signs of corrosion, leaks, structural damage, or deterioration. Evaluate
the tank's capacity, dimensions, material, and age to determine the extent of the overhaul
required.
Draining and Cleaning:Drain the tank completely to remove any remaining water. Clean
the interior surfaces of the tank thoroughly to remove sediment, algae, rust, and other
contaminants. Use appropriate cleaning agents, scrub brushes, and high-pressure washing
equipment for effective cleaning.
Structural Repairs:Welding, patching, or reinforcing may be necessary to strengthen the
structure and prevent future leaks or failures. Address any corrosion issues by removing rust
and applying protective coatings or linings to prevent further deterioration.
Surface Treatment:The tank's interior and exterior surfaces are treated to prevent
corrosion and prolong its lifespan. This may include applying protective coatings or linings to
prevent rusting and deterioration caused by exposure to water and environmental factors.
Replacement of Components: Any worn-out or malfunctioning components such as
valves, pipes, fittings, seals, and gaskets are replaced with new ones to ensure proper
functioning and prevent leaks or failures.
Testing and Calibration:The tank is tested to ensure it meets water quality standards and
operational requirements. This may involve pressure testing, leak detection, flow rate
measurement, and calibration of level indicators and sensors.
Refilling and Commissioning:Once the tank has been overhauled and tested, it is refilled
with water and commissioned for use. Operational checks are performed to verify that the
tank is functioning correctly and that water is being stored and distributed as intended.
Maintenance Plan: A maintenance plan is established to ensure regular inspections,
cleaning, and maintenance tasks are carried out to prevent future issues and prolong the
lifespan of the tank.

ACTIVITIES OF MR/ TANK SECTION

The activities of an MR (Material Requisition) or Tank Section typically involve managing the
procurement, storage, distribution, and maintenance of materials or substances stored in
tanks within an organization.
 AAR’H’ TYPE TIGHT LOCK COUPLER

• IR introduced High Tensile AAR „H‟ type Tight Lock Centre Buffer Coupler on
passenger coaches with the view to have longer train rakes, higher speed and
safety features.
• AAR „H‟ type Centre Buffer Coupler (CBC) was first time used in 24 imported
Alstom /LHB coaches.
• The trains fitted with these couplers, when put in service, “Jerks” were
observed.
• The AAR H coupler has been supplied by FTIL and Escorts which are fitted
Draft Gear, all were observed to have Jerks.
• Longitudinal jerks in mainline coaches equipped with CBC have been a major
concern since introduction of CBC.
• Several measures were taken in the past to reduce the longitudinal jerks but
they resulted in minor improvements only
• The specification of CBC CK-009 (Rev.2) does not specify the type of draft
gear. Suppliers are free to supply any type of draft gear such as single pack,
twin pack, floating plate or any other design-
• On the basis of a systematic study of design of CBC, a new specification of CBC
has been made. In the new specification, balanced type draft gear has been
specified.
• The couplers to this new specification have been mostly supplied to IR by M/s
Faiveley, M/s ASF-Keystone and M/s Escorts.
The coupler provides a means of mechanically connecting individual adjacent vehicles to
make a train. The coupler is located at both ends of each vehicle. When connected to a
coupler of an adjacent vehicle, it allows the vehicles to move independently to accommodate
track curvature and elevation change while remaining connected (coupled) together. The
coupler is opened manually using the coupler operating rod and is closed automatically
when the couplers on adjacent vehicles are mated. The coupler automatically locks when
fully mated. LHB coaches have been provided with tight lock centre buffer couplers instead
of screw coupling. Couplers are AAR-H type and have anti-climbing features because of
vertical interlocking.
Couplers have adequate strength for:
Satisfactory hauling of a train of 26 coaches at 110 kmph
• Satisfactory hauling of a train of 18 coaches at 160 kmph
• Coupling is possible under angular misalignment both horizontally and vertically. The
coupler permits coupled trains to negotiate vertical and horizontal curves and allows
rotational movements. The draw gear ensures cushioning effective in both buff and draft
 G-SHOP

HAND PALLET TRUCK

A hand pallet truck, also known as a pallet jack, pallet pump, or jigger, is a manual tool used
to lift and move pallets within a warehouse or other industrial settings. It is a simple yet
essential piece of equipment designed to efficiently transport heavy loads on pallets without
the need for powered machinery.
Operation of a Hand Pallet Truck:
To operate a hand pallet truck, follow these steps:
• Position the forks of the pallet truck under the pallet.
• Pump the handle to raise the forks off the ground.
• Once the load is lifted, steer the pallet truck to its destination.
• To lower the load, slowly turn the release valve on the pump handle.

Advantages of using a hand pallet truck:

• Hand pallet trucks are more affordable than powered equipment such as forklifts
• They can easily navigate in tight spaces where larger machinery may struggle to
operate.
• Hand pallet trucks are simple to operate and require minimal training.
• They can be used in various industries for transporting goods over short distances.
 COMPONENTS OF HAND PALLET TRUCK
• The forks are the two prongs at the front of the pallet truck that slide under the pallet
to lift and move it.
• The pump handle is used to raise and lower the forks by pumping it up and down.
• Hand pallet trucks have wheels that allow for easy manoeuvrability and
transportation of heavy loads.

DAMPER
A damper is a mechanical device that is used to reduce the oscillations or vibrations in a
mechanical system. It works by converting the kinetic energy of the oscillating system into
heat energy, which is then dissipated into the surrounding environment. This helps to
dampen the motion and bring the system to a state of rest more quickly. Dampers are
commonly used in various mechanical systems, including automotive suspensions, building
structures, and machinery.

Types of Damper

• Secondary Vertical Damper:A secondary vertical damper is a type of damping

system used in various engineering applications to control vibrations and oscillations
in structures. These dampers are designed to provide additional damping capacity
beyond the primary damping system, typically in the form of tuned mass dampers or
other vibration control device.
• Secondary Lateral Damper:A secondary lateral damper is a type of suspension
component used in automotive and other vehicle applications. Its primary function is
to reduce the lateral movement of the vehicle’s body during cornering, providing
 improved stability and handling. By damping out unwanted motion, the secondary
lateral damper contributes to a more comfortable and controlled ride experience.
• Yaw Dampers:Yaw dampers, also known as yaw stabilizers, are devices designed to
control the yaw motion of an aircraft or other rotating structures. Yaw motion refers to
the rotation of an aircraft around its vertical axis, which can cause instability and
affect the overall performance and safety of the vehicle. Yaw dampers play a crucial
role in maintaining stability and reducing oscillations during flight.

Applications Of Dampers:

a. Dampers are used in building structures to reduce the impact of wind and
seismic forces and improve occupant comfort.
b. Dampers are used in industrial machinery to reduce vibrations and improve
machine performance and accuracy.
c. Dampers are used in high-precision machinery to reduce vibrations and
improve machine accuracy and repeatability.
d. Dampers are used in aerospace applications to reduce vibrations and improve
aircraft stability and control.

Design Consideration Of Damper

➢ The damping ratio is the ratio of the actual damping coefficient to the critical
damping coefficient. A higher damping ratio results in a faster decay of oscillations.
➢ The frequency range of the system must be considered when designing a damper.
The damper must be designed to effectively dissipate energy within the desired
frequency range.
➢ The operating conditions of the system, such as temperature, pressure, and load,
must be taken into account when designing a damper. The damper must be able to
operate effectively under these conditions.
➢ The mounting configuration of the damper must be considered when designing a
damper. The damper must be mounted securely and properly aligned to ensure
effective operation.
➢ The maintenance requirements of the damper must be taken into account when
designing a damper. The damper must be designed for ease of maintenance and
repair.
 C-SHOP
BALL BEARING

A ball bearing is a type of rolling-element bearing that uses balls to maintain the separation
between the bearing races. The purpose of a ball bearing is to reduce rotational friction and
support radial and axial loads. Ball bearings are commonly used in various mechanical
applications, including automotive components, industrial machinery, household appliances,
and more.

Structure Of Ball Bearings

Ball bearings typically consist of inner and outer races, balls, retainers, and closures. The
inner race is mounted on the rotating shaft, while the outer race is usually stationary. The
balls are positioned between the races and roll smoothly, reducing friction. The retainers
hold the balls in place within the bearing assembly, preventing them from rubbing against
each other. Closures are used to shield the bearing from contaminants and retain
lubrication.

Advantages Of Ball Bearings

• Ball bearings reduce friction compared to sliding bearings, leading to improved
efficiency.
• They can operate at high speeds due to their low friction design.
• Ball bearings provide precise rotational movement, crucial for many applications.

Applications Of Ball Bearings:

• Used in wheel hubs, transmissions, engines, steering systems, etc.
• Employed in pumps, compressors, conveyors, electric motors, and more.
 M-SHOP
CORROSION AND FURNISHING HEAVY REPAIR SECTION
The following are the basic work done in M- Shop (Maintenance):
• Primarily overhauling of ICF, BEML and RCF coaches is done.
• Coach replacement and dismantling.
• Dismantled parts are sent to respective shops for analysis.
• Basic parts of a coach- Body and Bogie
• Lower portion of a body comprises of Headstock, Outer Headstock and Inner
Headstock.

Corrosion is a natural process that occurs when metal is exposed to various environmental
factors such as moisture, oxygen, and chemicals. It leads to the deterioration of the metal
surface, weakening its structural integrity over time. To combat corrosion and ensure the
longevity of metal structures, heavy repair sections are often used to replace or reinforce
corroded areas.

HEAVY REPAIR SECTIONS

Heavy repair sections are prefabricated metal components designed to replace damaged or
corroded sections of a structure. These sections are typically made from materials that are
resistant to corrosion, such as stainless steel or galvanized steel. They are manufactured to
match the dimensions and specifications of the original structure, making them easy to
install and ensuring a seamless repair process.

CORROSION IN ICF COACHES

Corrosion in Integral Coach Factory (ICF) coaches is a significant concern for the railway
industry. ICF coaches are prone to corrosion due to various factors such as exposure to
environmental elements, moisture, and operational conditions. Corrosion can compromise
the structural integrity of the coaches, leading to safety hazards and increased maintenance
costs.

Causes of corrosion in Indian Railway coaches:

• Water seepage through the flooring to the top of trough floor

• Leakage of water through lavatory flooring.
• Missing of commode chute and drain pipe.
• Defective water pipe fittings.
• Absence of surface preparation during replacement of commode and drain pipe.
• Habits of flushing the flooring with the water jet for cleaning.
• The conditions of air trapped in between trough floor and flooring due to climate
change.
• Striking of flying ballast when the train is running.

Areas prone to high rate of corrosion in passenger coaches are:

Trough floor:Areas adjacent to lavatory, doorway, and luggage compartment in SLR and
kitchen area of pantry car.
Head stock:Areas inner and outer head stock, stiffener, protection tube area, support tube
area etc.
Side wall bottom:Area below lavatory and between body side pillars.
Body pillars:Bottom portion of pillar near doorway and lavatory area.

Cross bearers:Joint between sole bar and cross bearers.

Body side door:Bottom of door due to accumulation of dust.
Battery boxes:Corrosion due to acid action.
Roof:Ventilator and area around it.
Vulnerable members and locations:
• Tubular frame below lavatories and trough floor in bays adjoining lavatories in all
types of coaches and under the luggage compartments of SLR and parcel vans and
kitchen area of pantry cars.
• Sole-bar, body pillars, turn-under in the bays under and adjoining lavatories in all
types of coaches and in addition kitchen area of pantry cars.
• Sole bars, turn under and pillars above lifting pads.
• Sole bars and pillars behind the sliding door pockets of SLR‟s & parcel vans.
• Sole bars, pillars and turn-under at door corners.
• Side panels below window in non ac coaches and lower portion of body pillars.

Corrosion repairs
Material & treatment of components
It is essential to use low alloy high tensile corten type steel sheets and plates to IRS-M41-
1974for repairs of integral coaches. The thickness of steel sheets/plates to be used shall be
as under:
• All body shell replacement components less than 5 mm thickness used for corrosion
repairs should be hot phosphate and applied with protective paints. Cold phosphate
should be done body wall side panel areas where welding has been carried out on
hot Phosphate components.
• Zinc rich primer should be used where spot welding is done. Components of 5 mm
ormore thickness should be grit blasted and immediately followed by application of
red oxide zinc chromate primer.
• Welding electrodes and paints should be of the prescribed quality conforming to the
relevant IS/ IRS specification. Where the corrosion noticed is of a very minor nature
and has just started, there is no need to renew parts. The paint and rust should be
thoroughly cleaned to reach the bare metal and the surface treated with two coats of
primer. In addition under frame members should be given four coats of bituminous
solution.
• Design improvements / modifications:Several design improvements/
modifications for eliminating/minimising corrosion have been issued by the
RDSO/ICF from time to time. Brief details of these together with the action to be
taken by the railways are given below:
1. FRP tissue sandwiched between layers of bitumen since 1982 FRP tissue
sandwiched between bituminous coats has been laid on trough floor, sidewall and
body pillars up to waist rail height and the entire under frame. On these post 1982
coaches, whenever corrosion repair is carried out on portion laid with FRP tissue,
patch repair of the FRP tissue should also be done to the extent to which the original
lining is removed for repairs to the corresponding parts.
2. Sealing of window sills: To prevent seepage of water through the gap between the
sidewall and window sill, a modified arrangement as per RDSO sketch - 76014 has
 beenintroduced on all coaches who are being turned out by ICF from 1975 onwards.
This modification has not eliminated the seepage of water and problem still persists.
Further design modification is required to mitigate the problem.

Galvanic Corrosion cells: ICF coaches –

• Concentration cells.
• Sole bar, Trough floors, Turnunders & body pillars in vulnerable regions, roof
ventilators & water wriggles.
• Stress cells Headstocks & Trough floors {in other non vulnerable regions} where there
is cold press bending sans any heat treatment / none stress relieved welding.
• Dissimilar material contact cells MS Crossbars supporting SS Trough floors & MS
lavatory U channels {2mm thick} supporting SS lavatory inlays.
 MR/ L-BAY-SHOP
The MR-L-BAY shop in Indian Railways Liluah is a maintenance facility that is used for the
repair and maintenance of railway wagons. The term “MR-L-BAY” stands for “Maintenance
Repair - Loco Bogie Assembly Yard.” This facility is located in Liluah, which is a suburb of
Kolkata in the state of West Bengal, India.
The MR-L-BAY shop at Liluah is equipped with modern machinery and tools to carry out
various maintenance tasks on railway wagons. It plays a crucial role in ensuring the smooth
operation of the Indian Railways network by keeping the wagons in good working condition.
The shop undertakes repair and maintenance work on different types of wagons, including
goods wagons, passenger coaches, and other rolling stock. The skilled workforce at the MR-
L-BAY shop is trained to handle a wide range of repair tasks, from routine maintenance to
major overhauls.
Overall, the MR-L-BAY shop in Indian Railways Liluah serves as a vital facility for maintaining
the operational efficiency and safety of the railway rolling stock in the region.

BOGIE
A bogie in Indian Railways is a wheeled chassis or carriage that supports one or more railway
vehicles. It is an essential component of the railway system, providing structural support,
stability, and carrying capacity to carriages. In Indian Railways workshops, bogies undergo
regular maintenance, repairs, and modifications to ensure their safe and efficient operation.
BOGIE FRAME:The frame is the primary structural component of a bogie. It is designed to
withstand the weight and stresses of the vehicle and provide a stable platform for the
wheels, suspension system, and other components. The frame is usually made of welded
steel or aluminium alloys and is designed to be lightweight yet strong enough to support the
load of the vehicle.
BOGIE TRANSOM: Transverse structural member of bogie frame which also supports the
car body guidance parts and the traction motors.
BRAKE CYLINDER:The brake cylinder in a bogie is an essential component of a railway
vehicle’s breaking system. A bogie is a frame supporting two or more wheels and carrying
the entire weight of the train. The brake cylinder plays a crucial role in applying brakes to the
wheels, thus slowing down or stopping the train.

PRIMARY SUSPENSION COIL: The primary suspension coil is a component of the

suspension system that helps absorb shocks and vibrations generated while the vehicle is in
motion. It is typically located between the bogie frame and the axle, serving as a critical
element in ensuring a smooth and stable ride.
MOTOR SUSPENSION TUBE: The motor suspension tube in a bogie is a crucial
component that plays a significant role in the suspension system of a train. In a railway
bogie, the motor suspension tube is responsible for supporting and connecting the motor to
the bogie frame while also providing damping and cushioning effects to absorb shocks and
vibrations during train operations.
GEARBOX:A gearbox in a bogie, also known as a wheel truck or a chassis, is a crucial
component in various types of vehicles, especially in trains and trams. The gearbox in a
bogie serves the purpose of transmitting power from the engine to the wheels, allowing the
vehicle to move efficiently. It plays a vital role in controlling the speed and torque of the
wheels, enabling smooth acceleration and deceleration.
NEUTRAL SECTION SWITCH DETECTOR:A neutral section switch detector in a bogie
is a crucial component in railway systems that helps ensure the safe and efficient operation
of trains. The detector is designed to identify neutral sections along the railway tracks, which
are areas where the electrical potential is zero. These sections are essential for various
reasons, such as isolating different segments of the track for maintenance or safety
purposes.
SHOCK ABSORBER:To reduce the effects of vibration occurring as a result of the wheel
interface.

OVERHEAD CRANE:An overhead crane in bogie, also known as a bogie crane or a gantry
crane, is a type of crane that is mounted on a movable carriage, which runs along a track
system. This allows the crane to cover a large area and access various points within a
workspace. The term “bogie” refers to the wheeled undercarriage that supports the crane’s
bridge and trolley.

APPLICATIONS:
• In automotive, aerospace, and heavy machinery industries, these cranes assist in
assembling large components, transporting raw materials, and moving finished
products within production facilities.
• In shipyards, overhead cranes in bogie are used to construct and repair ships,
handling heavy components such as engines, propellers, and hull sections.
• In construction sites, overhead cranes in bogie help lift and move heavy building
materials such as steel beams, concrete panels, and HVAC equipment.
 H-SHOP

MILLWRIGHT WORKSHOP(H-SHOP):
The major activities involved in Millwright Work Shop are:

➢ Maintenance of all Machinery and plant of CW/PER including carrying out schedules
and Breakdown.
➢ Operation of Steam boiler and supply of steam, operation and Maintenance of water
pumps, Air Compressor, Compressed air pipes and ETP systems.
➢ Re-building and maintenance furnaces.
➢ Support to core activities of coach and wagon POH by manufacture of critical items,
gadgets, improvement apparatus etc.,
➢ Receipt and commissioning of machines, Condemnation and disposal of machines,
Re-siting machines, foundation of machines.
➢ Maintenance of CO2 and inverter arc welding plants and mechatronics lab activities.
➢ Maintenance of R.O. plants
➢ Repairs to Hydraulic Jack, Screw Jack, Machine chucks, extractors etc., of shops and
divisions.
➢ Bailing out water from pits during rain
➢ Assistance in fire fighting
➢ Lowering and raising of motors of EOT cranes, machineries, Traverses and Electric
hoists.
➢ Coordination and assistance to Engineering & Electrical departments.
VARIOUS SECTIONS IN MILLWRIGHT SHOP:
➢ General Carriage shop
➢ Crane & Traversers
➢ Air Compressor Section
➢ CR complex Machine Maintenance section
➢ Machine Section
➢ Spring Shop maintenance section
➢ Up Country section
➢ WR machine maintenance section & Mechatronics lab
➢ Development & Jack section

JOB RESPONSIBILITIES :-
DEVELOPMENT SECTION :

❖ Maintenance of machines.
❖ Manufacture of fixtures and gadgets.
❖ GA card punching clock maintenance.
❖ Maintenance of hand tools for different shops.
❖ Developmental works to improve the quality of work.
❖ Maintenance of 10 ltrs. RO Plants.
❖ Fabrication of Stainless Steel Under slung water tank (Direct Incentive work)
on requirement.
❖ Fabrication work for tanks.
 JACK SECTION :

❖ Repair &Overhauling of Jacks in CW/PER and MAS division.

❖ Machine chuck repair work in CW/PER and Madras division
❖ M&P records maintenance.
❖ Maintenance of stores.
❖ To Coordinate for AMC to fire Extinguishers.

CRITICAL ANALYSIS :-
MILL WRIGHT (GENERAL CARRIAGE SHOP) :

Important activities of GC Shop are -

❖ Cranes, Traversers, Hoist and Winches maintenance

❖ Wagon shop machine maintenance
❖ Spring shop maintenance
❖ W&T and NMS maintenance
❖ Air Compressor maintenance (centralized & Decentralised)
❖ CR complex machine maintenance
❖ Heavy repair activities
❖ Out-station machine maintenance
❖ Development & CO 2 plant maintenance section
❖ Machine and Jack repair section
 MR/ABK-SHOP
AIR BRAKE SYSTEM

In Air Brake system compressed air is used for operating the brake system. The locomotive compressor
charges the feed pipe and the brake pipes throughout the length of the train. The feed pipe is connected
to the auxiliary reservoir and the brake pipe is connected to the brake cylinder through the distributor
valve. Brake application takes place by dropping the pressure in the brake pipe.

Principle of operation of twin pipe graduated release air brake system.

(a) Charging the brake system

• Brake pipe throughout the length of train is charged with compressed air at 5 Kg/cm2.
• Feed pipe throughout the length of train is charged with compressed air at 6 Kg/cm2.
• Control reservoir is charged to 5 Kg/cm2.
• Auxiliary reservoir is charged to 6 Kg/cm2.
b) Brake application stage
• For brake application the brake pipe pressure is dropped by venting air from the driver’s
brake valve.
• Subsequently the following actions take place
• The control reservoir is disconnected from the brake pipe.
• The distributor valve connects the auxiliary reservoir to the brake cylinder and the brake
cylinder piston is pushed outwards for application of brakes.
• The auxiliary reservoir is however continuously charged from feed pipe at 6 Kg/cm2
Brake release stage:
• Brakes are released by recharging brake pipe to 5 Kg/cm2 pressure through the driver’s
brake valve.
• The distributor valve isolates the brake cylinder from the auxiliary reservoirs.
• The brake cylinder pressure is vented to atmosphere through DV and the Brake cylinder
piston moves inwards.
Emergency application and working of Distributor valve (C3W)
During emergency application the brake pipe pressure is reduced rapidly to 0 kg/cm2 by
the driver's brake valve. Because of this drop the position of the various valves will be as
described below.
Main valve: With drop in BP pressure to 0 kg/cm2 differential pressure acts across the
large diaphragm. As a result the hollow stem is moved in upward direction and pushes the
check valve there by opening the passage for entry of auxiliary reservoir pressure at top
portion of main valve. This pressure then gets a way to brake cylinder through limiting
device. The brake cylinder thus gets charged with the compressed air. This pressure is
known as BC-pressure.
Limiting Device:The auxiliary reservoir pressure which entered into the top position of
main valve now enters the limiting device through the valve which is held open. From limiting
device air pressure now enter the brake cylinder. When the BC pressure rises to 3.8 kg/cm2
the upwards force on the diaphragm lifts the guide and the valve at the bottom of the
limiting device gets closed. Thus further entry of air into the brake cylinder stops. When the
brake cylinder pressure reaches 3.8 kg/cm2 this pressure i.e. BC pressure act on
• Top face of small diaphragm of main valve
• Bottom face of upper diaphragm of cut off valve
• Top (small chamber) of quick service valve
Now because of this BC pressure acting at main valve small diaphragm, the hollow stem is
pulled down. As a result the check valve at top comes down to close stage and assume lap
position with the hollow stem closing further entry of AR pressure.
Cut off valve :In cut off valve the bottom face of the upper diaphragm is subjected to BC
pressure because of which the guide is lifted. Also the upper portion of lower diaphragm is
subjected to CR pressure, which pushes the total assembly downwards. This action closes
the valve of cut off valve, there by isolating it from control reservoir pressure.
Quick Service Valve :In quick service valve BC pressure acts at the top of valve and
control reservoir pressure act at top face of upper diaphragm. As a result the stem is pushed
down. The valve at the bottom gets opened. Now as the BP pressure inside the DV is at "O"
kg/cm2 the residue BP pressure from the bulb of quick service valve will flow back and vent
to atmosphere with the BP line.
Graduated Application:During graduated brake application the brake pipe pressure is
dropped in steps by driver's brake valve. The movement of various valve assemblies is
almost in the same direction as during emergency application, but their movement is
comparatively less. In the main valve however after each application the hollow stem
assumes the lap position with the check valve. In addition to this during graduated
application the bottom valve of limiting device is held open to allow compressed air to enter
into brake cylinder. When BC pressure reaches 3.8 kg/cm2 the bottom valve in the limiting
device gets closed. Similarly at the time of full service application as the BC pressure

Manual Release:Double release valve provides for accelerated manual brake release,
which is particularly useful during shunting operation. A short pull on the lever of double
release valve is all that is needed. This action opens the control reservoir release check
valve, which is then held open by the locking rod. Venting of control reservoir through the
open control reservoir release check valve brings the main valve to release position and
exhausts the brake cylinder pressure through the hollow stem.

Passenger Emergency Alarm System

Passenger emergency alarm system consists of two components:
• Passenger Emergency Alarm Signal Device (PEASD).
• Passenger Emergency Alarm Valve (PEAV).
These two components in combination give an indication to the driver that some passenger
is in need to stop the train. The indication is transmitted from the coach when the passenger
pulls the chain.

Passenger Emergency Alarm Signal Device

Passenger Emergency Alarm Signal Device (PEASD) is a manually operated pilot vent valve.
It is operated through mechanical force exerted by pulling the alarm chain provided inside
the coaches for emergency use. The passenger emergency alarm signal device does not
need any maintenance during normal service except when it is found damaged or is due for
periodic overhauling.
 MR/LHB-SHOP

• This shop deals with the maintenance of coaches of Rajdhani, Duronto.

• Produced by rail coach factory in Kapurthala, India.
• The coaches are designed for an operating speed up to 160 km/hr and could go up
to 200 km/hr.
• Indian Railways have decided to replace the conventional air-conditioned and non-
conditioned Integral Coach Factory made coaches with the LHB in all the trains by the
end of 2016.

FEATURES OF LHB COACHES

Corrosion Free Coach
• Extensive use of Stainless steel and surface protection measures
Longer Coach
• Longer By 2.2 Meters (Approx) Than Conventional Coach
Light Weight Coach
• 10% lesser weight per meter length lesser than conventional coach
• Better Pay to Tare Ratio
Higher passenger comfort
• Ride Index 2.5 (Not exceeding 2.75)
 • Auto Closing Sliding Doors
• Wider Windows
• Modular Interiors
• Use of Fire Retardant Materials

Maintenance facilities of LHB coaches at Workshops

With the induction of LHB coaches in the services, workshops should have also the facility
for Periodic Overhaul/ Intermediate Overhaul (POH/IOH) 43 of LHB coaches including regular
maintenance. The structure and composition of LHB coaches are different from that of
conventional coaches. As such, specific infrastructure/facilities/M&P are required for
POH/IOH of LHB coaches. Audit reviewed the status of availability of infrastructure in
workshops over Indian Railways. Audit analyzed whether the infrastructure was adequate for
POH/IOH and other maintenance activities of LHB coaches.

Liluah Workshop is the only carriage maintenance workshop where POH of LHB coaches are
undertaken. Only infrastructure development work (facilities for overhauling of new
generation coaches including 26 m long coaches) was completed in December 2015. Works
of modernization of workshop, included creation of infrastructure for 24 m long LHB coaches
was sanctioned in 2008-09. Physical progress of these works was only 65 per cent. Another
work viz., capacity augmentation work for maintenance of 30 LHB coaches per month was
sanctioned in 2012-13. The physical progress of this work was only 29 per cent as of
November 2018. In reply, Railway Board stated (20 June 2019) that modernization and
capacity augmentation works at Liluah were being closely monitored. The target of POH of
LHB coaches has been enhanced to 562 coaches this year from 372 coaches last year. They
further stated that another work for creation of facility for POH of LHB coaches has been
sanctioned at ER’s Kanchrapara workshop. Railways need to complete the augmentation
work of existing workshop and creation of facilities in new workshops within a prescribed
time frame to cater to the existing requirement of POH of LHB coaches. This would also ease
the burden of existing Liluah Workshop.
BOLTS AND SCREW FOR MAINTAINENACE OF LHB BOGIE
MATERIAL COMPATIBILITY:. Choosing bolts and screws made from materials such as
stainless steel or alloy steel ensures corrosion resistance and durability in the demanding
railway environment.
STRENGTH REQUIREMENTS: The fasteners selected must meet or exceed the required
strength specifications to withstand the operational stresses experienced by LHB bogies.

Size and Thread Type: Proper sizing and threading of bolts and screws are essential to
ensure a secure fit and prevent issues like stripping or loosening over time.
Environmental Conditions: Considering factors like temperature variations, exposure to
moisture and vibration levels is crucial when selecting fasteners for LHB bogie maintenance.

SPECIFIED TORQUE FOR LHB FASTENERS

The specified torque for LHB (Linke-Hofmann-Busch) fasteners is crucial to ensure the
proper assembly and functioning of these components in various applications. LHB
fasteners are commonly used in the railway industry for assembling components like bogies,
under frames, and other structural elements of rail vehicles. The torque requirements for
these fasteners are determined based on factors such as the material of the fastener, the
thread type, the size of the fastener, and the application requirements.
DAMPERS
Each FIAT bogie uses 4 primary vertical, 2 secondary vertical, one secondary lateral and 2
yaw dampers. These are hydraulic shock absorbers to damp the accelerations caused due to
track irregularities and opposing force depending on the speed of the movement.

Axle Bearing
Cartridge Taper Roller bearing unit is being used on wheel sets of LHB design coaches.
These are self-contained, pre-assembled, pre-lubricated and fully enclosed units. These are
applied and removed from the wheel sets without exposing the bearing elements or
lubricant to avoid contamination or damage. There are total four bearing units (CTRBs) in
each bogie. One axle bearing on each axle is fitted with sensors for detecting speed (whose
signal is received and analyzed by the anti slipping system provided in all LHB Coaches). One
axle bearing on each bogie is fitted with a current return device and remaining one axle
bearing is without any attachment on each bogie. These bearings do not require any
maintenance in open line and are thus virtually maintenance free bearings.
Anti-Roll Bar
A torsion bar having two forks is provided between bogie frame transverse beam with the
help of two links to resist rolling motion of coach.
Rocker Device

The traction and braking force between bogie and body is transferred through a rocker
device located at the centre of the bogie approximately in the plane of axle.
The Future of LHB Coaches in Indian Railways

As Indian Railways modernizes and expands its network, the demand for LHB coaches will
remain strong, despite the increasing number of Vande Bharat trains. The railway system is
continuously integrating new technologies, such as the Train Collision Avoidance System
(TCAS) and the European Train Control System (ETCS), to enhance train safety and
efficiency. LHB coaches are well-equipped to integrate with these cutting-edge systems,
ensuring their relevance in the evolving rail landscape.
Moreover, Indian Railways is actively working on developing faster rail corridors to cater to
the growing need for rapid transportation. LHB coaches, with their ability to sustain higher
speeds and their lightweight design, are well-suited for these high-speed rail projects. As a
result, the future of LHB coaches in Indian Railways remains promising, with their versatile
and advanced design continuing to contribute to the modernization of the country's rail
infrastructure.
 K-SHOP

A train wheel or rail wheel is a type of wheel specially designed for use on rail tracks. A
rolling component is typically pressed onto an axle and mounted directly on a rail car or
locomotive or indirectly on a bogie, also called a truck. Wheels are cast or forged (wrought)
and are heat- treated to have a specific hardness. New wheels are trued, using a lathe. to a
specific profile before being pressed onto an axle. All wheel profiles. need to be periodically
monitored to ensure proper wheel-rail interface. Improperly trued wheels increase rolling
resistance, reduce energy efficiency and may create unsafe operation. A railroad wheel
typically consists of two main parts: the wheel itself, and the tire (or tyre) around the outside.
A rail tire is usually made from steel, and is typically heated and pressed onto the wheel,
where it remains firmly as it shrinks and cools. Monobloc wheels do not have encircling tires,
while resilient rail wheels have a resilient material, such as rubber, between the wheel and
tire.
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 size(mm) Axel wheel seat
journal centre dia. (mm)
(mm)
ICF 915 2159 120*113.5 172,0.25,0.35

BMEL 915 2210.2 120*179 171,0.45,0.63

The diameter of the wheel when it is condemned are –

Sl. No Type of Wheel Diameter in (mm)
1. ICF/BMEL SOLID 915-813
2. ICF TIRED 915-851
3. BMEL TIRED 915-839
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 consists 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.
 L-SHOP

This shop deals with the maintenance of various types of wagon.

The wagons are mainly categorized into four types:-
• BLC-BOGIE LOW CONTAINER PLATFORM WAGON
• BVZI-BREAK VAN FITTED WITH ICF BOGIE
• BOXN-BOGIE OPEN FITTED WITH AIR BRAKE WAGON
• BCN-BODY COVERED WAGON

The BLC stands for Bogie Low Container Platform Wagon. It is a type of railway wagon
specifically designed for transporting 20 and 40 ft. intermodal containers in single or double
stack configurations. The BLC has a carrying capacity of approximately 61 tons, allowing it to
transport significant amounts of cargo efficiently. These wagons are commonly used in rail
freight operations to move containers between different locations.
BVZI-BREAK VAN FITTED WITH ICF BOGIE is fitted with ICF coach bogies, designed to
enhance the comfort level of guards compared to the previous 4-wheeled BVZC. The model
comes with accurate details and options for display versions with plastic wheels and
couplers or an RTR version with metal wheels and Kadee couplers, replicating the
prototype’s features.
The BOXN-BOGIE OPEN FITTED WITH AIR BRAKE WAGON is a type of broad gauge open
wagon mounted on two cast steel high-speed bogies. It features four 22.91 axle load wheel
sets, cartridge type bearings with adaptors, and a single pipe air brake system. These wagons
are designed for high-speed heavy-duty transportation, typically used for carrying coal, various
ores and minerals, and other bulk materials that are not susceptible to natural hazards. They
are equipped with three doors on each side for easy loading and unloading.
 TOOL ROOM
This section is serving one of the most vital function of Tool Room i.e. storing and issuance
of Tools and instruments. The workload carried out by the staff of Tool Equipment section is
listed below:
a) Issuance of tools and instruments.
b) Arrange for repair of tools and instruments.
c) Accounting with record keeping of tools and instruments.
d) Identification of damaged tools and process for scraping.

Tool Room Operators in Indian Railways are tasked with tasks such as:
• They are responsible for inspecting, cleaning, and repairing tools to ensure they are in
good working condition.
• Operating various tools and equipment as required for different maintenance tasks
within the railways.
• Ensuring that all safety protocols are followed while handling tools to prevent
accidents and injuries.
• Keeping track of tool inventory, ordering new tools when necessary, and maintaining
records of tool usage.
 LATHE MACHINE

A lathe is a versatile machine tool used in various industries such as woodturning,

metalworking, and glass-working. It rotates a workpiece to perform operations like cutting,
sanding, drilling, and turning. Lathes have been integral throughout history, with evidence of
their existence dating back to ancient civilizations like Ancient Egypt and Mycenaean Greece.
The lathe played a crucial role in the Industrial Revolution, leading to the development of
other machine tools.

Components of Lathe Machine:

Bed: The horizontal beam supporting the lathe.
Headstock: Contains spinning bearings and the spindle that rotates the workpiece.

Spindle: Driven by power sources like electric motors or treadles.

Speed Mechanisms: Various mechanisms for changing spindle speeds, such as cone
pulleys or gear trains.
Tool Room Production Worker:
A) Mechanical - Knowledge of machines and tools, including their designs, uses, repair, and
maintenance.
B) Production and Processing - Knowledge of raw materials, production processes, quality
control, costs, and other techniques for maximizing the effective manufacture and
distribution of goods.
C) Analytical Thinking – Capability of analyzing information and using logic to address work-
related issues and problems.
D) Innovation - Competencies in creativity and alternative thinking to develop new ideas for
and answers to work-related problems.
E) Operate fork-lift, pallet jack and other heavy equipment when necessary

Calibration Section:
Calibration of measuring instruments and gauges is one of the most vital works of Tool
Room. The staffs of Calibration section carries out the calibration work of gauges and
instruments of different shops of Liluah workshop and other places over Eastern Railway.
The workload carried out by the staff of Calibration section in regular manner is listed below
in details:
a) Calibration and repair of around 2500 nos. of gauges and instruments of Liluah
workshops and units all over from Eastern Railway with an interval of every 6 months.
b) Monitoring and maintaining record of all the Calibrations done by the Section.
c) Monitoring and maintaining record of all the Calibrations of Master Gauges and
Instruments done by outside agencies.