ON
INDIAN RAILWAYS
Submitted By:
Nitish Kumar (40396204915)
Anshul Gupta (41796204915)
Aditya (35196204915)
It is hereby certified that the work which is being presented in the B.Tech. industrial
training report entitled – “INDIAN RAILWAYS”, in partial fulfilment of the
requirements for the award of degree of BACHELOR OF TECHNOLOGY and
submitted in the department of Electrical and Electronics engineering of DR.
AKHILESH DAS GUPTA INSTITUTE OF TECHNOLOY AND MANAGMENT,
NEW DELHI -110053 is an authenticate record of our genuine work done carried out
during the period from June 2018 to July 2018. Any resemblance to some other work,
print or publishing is purely coincidental and any such resemblance is an original work
of the concerned personnel or organization. The data has been directly taken from
references.
The matter presented in the thesis has not been submitted by us for the award of any
other degree of this or any other university or institute.
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ABSTRACT
Northern Railway Workshop, Dayabasti has been initially providing services for implant
training over the period. Over the year, this workshop has diversified and increased its
activity and presently it undertakes implant training, diesel hydraulic locomotives, train
and road cranes. It also manufactures large no of locomotives components required by
the workshop and division of central railway.
This report also gives information on various component of Engine, cranking of the
Motor. Also various Sections and components information.
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ACKNOWLEDGEMENT
I would like to express my deep gratitude to Ms. Savita, Event Coordinator for her
valuable guidance. I would like to extend my thanks to Mr. Ajit Kumar Sharma, Head,
Department of Electrical & Electronics Engineering for his time to time suggestions
to complete my industrial training report work. I am also thankful to Prof. (Dr.) Sanjay
Kumar, Director, ADGITM, Delhi for providing me the facilities to carry out my
industrial training report.
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TABLE OF CONTENTS
CANDIDATES DECLARATION.................................................................i
CERTIFICATES............................................................................................ii
ABSTRACT....................................................................................................v
ACKNOWLEDGEMENT.............................................................................vi
TABLE OF CONTENTS...............................................................................vii
LIST OF FIGURES........................................................................................ix
CHAPTER 1 INTRODUCTION………………………………...…1
1.1 Division in Indian Railways…………………………………………......2
1.2 About Dayabasti Mechanical shop…………………………………......3
1.3 Statistics and Specification……………………………………………...3
CHAPTER 2 MACHINE SHOP…………………………………...4
2.1 Numerical Control……………………………………………………….4
2.2 Computer Numerical Control…………………………………………..4
2.3 Direct Numerical Control……………………………....……………….4
2.4 Manually Operated Machine…………………………...……………....5
CHAPTER 3 WHEEL SHOP……………………...……………….7
3.1 Wheel Testing & Machining……………………………..……………...8
3.2 Zyglo Testing……………………………………………..………………9
CHAPTER 4 SPRING SECTION…………………..……………...10
4.1 Spring Scraging……………………………………………..…………....12
4.2 D’ Buckling…………………………………………………...…………..12
CHAPTER 5 HEAT TREATMENT SHOP…………….…………13
5.1 Different types of Heat Treatment Process…………………...………..13
5.2 Iron Carbon……………………………………………………..……….14
CHAPTER 6 JIG & FIXTURE SHOP…………………….………15
6.1 Jigs………………………………………………………………….…….15
6.2 Fixture………………………………………………………………..…..15
6.3 Design of Jig & Fixtures………………………………………………...16
CHAPTER 7 BRAKING SYSTEM……………………………......17
7.1 Air Braking System……………………………………………….…......17
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7.2 Vacuum Braking System…………………………………………….….18
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LIST OF FIGURES
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CHAPTER 1
INTRODUCTION
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14. South east central-SECR-Bilaspur
15. West central railway-WCR-Jabalpur
16. Western railway-WR-Mumbai
17. Kolkata Metro-Kolkata
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CHAPTER 2
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, Aluminium - 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:-
Numerical control.
Computer numerical control.
Direct numerical control machine.
2.1 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.
2.2 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.
2.3 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.
These sections are:-
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2. Milling section.
3. Drilling section.
4. Central lathe section.
5. Heavy machine section
Fig 2.1: DIRECT NUMERICAL CONTROL
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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.
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CHAPTER 3
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 Axel wheel seat dia.
journal centre size(mm) (mm)
(mm)
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3.2 ZYGLO TESTING
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CHAPTER 4
SPRING SECTION
In this section the helical and leaf spring are prepared. For this purpose there
certain machine for testing, grading and repairing it.
Visual and magnetic crack detection. The visual test with the help of
magnifying lens and glass the spring 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.
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CAUSE PERCENTAGE OF FAILURE
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4.1 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:-
Over camber of the spring.
Short camber of the spring.
Leaf broken.
Gap between the leaves of the spring
4.2 D’ BUCKLING
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CHAPTER 5
HEAT TREATMENT SHOP
1. Hardening.
2. Tempering.
3. Austempring.
4. Martempring.
5. Annealing.
6. Stress relieving.
7. Spheroid zing.
8. Normalizing
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9. Case hardening.
10.Cyaniding.
11.Flame hardening.
12.Induction hardening.
13.Nitriding.
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CHAPTER 6
JIG AND FIXTURE SHOP
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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.
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CHAPTER 7
BRAKING SYSTEM
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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.
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CHAPTER 8
SHELL SHOP
Cause of Corrosion:-
1. Water Sleepage
2. Air-Trap between Floor and Plywood
3. Flying Blast (due to formation of spot)
1. Under Frame
Sole Bar
Head Stock Assembly.
Body Bloster Assembly.
Through Floor.
Crops Bearer.
Tubular Structure
2. Side Bar
3. Roof
4. End Bar
5. Centre Pivot (guide of turning of train)
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4. Liquefied Petroleum Gas
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CHAPTER 9
MATERIAL HANDLING SYSTEM
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Fig 9.1: OVER HEAD CRANE
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CONCLUSIONS
1. Principles for layout plans and sectioning diagrams for 25kv a.c.
traction
These principles for preparation, checking and finalization of
overhead equipment layout plans, have been framed for
standardization and guidance of Railways / Railway Electrification
Projects.
The electrical conductors over the track together with their
associated fittings, insulators and other attachments by means of
which they are suspended and registered in position is known as
Over Head Equipment’s.
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2. Pantograph
A collapsible device mounted on and insulated from the roof of an
electric engine or motor coach for collecting current from the
overhead equipment is known as Pantograph.
When any part of pantograph comes in between overhead wires or
vice versa, panto entanglement takes place.
OHE defects and Pantograph defects are few reasons of Pantograph
entanglement.
4. Traction Motor
A traction motor is an electric motor used for propulsion of a
vehicle, such as an electric locomotive or electric roadway vehicle.
Traction motors are used in electrically powered rail vehicles such as
electric multiple units and other electric vehicles such as electric milk
floats, elevators, conveyors, and trolleybuses, as well as vehicles with
electrical transmission systems such as diesel-electric, electric hybrid
vehicles and battery electric vehicles.
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REFERENCES
[8] www.irieen.indianrailways.gov.in/view_section.jsp/lang=0,296,437
[9] www.irieen.indianrailways.gov.in/view_section.jsp/lang=0,296,438
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