PRESENTATION ONVocational Training at

Coach Rehabilitation Workshop Bhopal

Coach rehabilitation workshop is located near Nishatpura area in the city Bhopal.

The workshop was started in the year 1989 at a project cost of approx. Rs. 64.97 crore for Mid-life Rehabilitation (MWR) of Indian Railway coaches.

CRWS has so far turned out more than 7000 coaches including more than 500 AC coaches.

During 2010-11 it has achieved best ever production of 571 coaches.

INTRODUCTION

During MLR entire coach furnishing is stripped off and renovated.

The bogie assembly and sub-assemblies are repaired or reclaimed or replaced as the case may be, based on the service & utility factor.

A newly prepared coach has a life span of around 25-30 years.

In MLR a 10-15 year old coach is brought to the workshop and repaired, which increases its life by around 10-15 years.

CRWS’s quality, environment, occupational health & safety management systems continue to be certified to ISO 9001, 14001 & OHSAS 18000.

DRDO and Indian railways have prepared a bio-toilet which are being fitted in every passenger coaches which comes to CRWS.

Services offered:- MLR of coaches in the age group of 12-15 years MLR of AC coaches MLR of Rajdhani Express coaches MLR of end on generation coaches

Pocket Yard

Lifting Bay

Strip Shop & PCR

Carpentry Shop

Final Shop Paint Shop

Furnishing Shop

Bogie & Wheel Shop

Shell Component

Shop

Body Repair Shop &

Air brake shop

In

OUT Fig. Layout of CRWS Bhopal

THE MAIN COMPONENTS OF CRWS ARE :-

1. Pocket Yard

2. Lifting Bay

3. Stripping and PCR shop

4. Wheel and Bogie shop

5. Carpentry Shop

6. Body Repair and air brake Shop

7. Paint Shop

8. Furnishing Shop

9. Final Shop

Pocket Yard1.The mid life coach brought for

repair enters here through BHOPAL JUNCTION STATION.

2. The coach is inspected, numbered according to location from which is brought to CRWS and time of entering the yard.

LIFTING BAY1. The coach is lifted here, bogie and wheel are

disassembled.2. BOGIE ASSEMBLY is sent to the bogie shop while the

wheel assembly is sent to the wheel shop.3. Upper portion containing the main portion of the coach

is sent to the PCR shop for stripping.

LIFTING BAY

STRIPPING & PCR SHOP The work of stripping of the internal as well as external part of coach body is done in this shop and also checking of corrosion affected area is done here.

In this shop fittings are stripped off to get bare shell for corrosion repairs.

Cutting of body side panels by “air plasma cutting” is done in this shop.

Wall panels, flooring, lavatory, seats, berths, windows is removed.

After this all the mechanical fitting is send to carpentry shop for repair & the coach is sent to the body repair shop.

BOGIE SHOP1. This is one of the most important shop in the workshop.2. The disassembled bogie from coach is brought here,

wheel assembly is removed and sent to the wheel shop.3. Bogie is further disassembled into smaller parts.

bogie assembly shop

A bogie is a wheeled wagon or trolley. In mechanics terms, a bogie is a chassis or framework carrying wheels, attached to a vehicle.

Usually the train floor is at a level above the bogies, but the floor of the car may be lower between bogies.

Axle, Wheel & Axle Box assembly

These wheels are having wear adapted profile to RDSO drawing.

BOGIE ASSEMBLY

SPIRAL SPRING

1. Inspection of side bearer and centre pivot.2. Lifting the bogie to take out the wheel base.3. Remove the frame of lifted bogie and place it with other

frames.4. Putting the bogie frame and spring in the wash tank.5. Sand blasting of bogie components.6. Shot blasting of spring and cleaning.7. Magna-flux test, grading and load test of spring.8. Painting of spring through dipping technique.9. Magna flux test of draw bar.10. Cleaning of bogie and spring through high pressure jet.11. Disassembling of bogie components. 12. Inspection of the components.13. Bushing and de-bushing of brake gear components14. Overhauling of bogie components.15. Assembling of bogie.16.Bogie testing and inspection.17. complete bogie is sent to the final shop.

PROCESSES IN BOGIE SHOP

BOGIE FRAMES

Side bearer

COMPONENTS OF BOGIE ASSEMBLY

WHEEL SHOP1. After removal of wheel in bogie shop, they come in wheel shop.2. Here the inspection of wheel is done by checking its diameter which

should be in the range 837mm(lower limit) to 915mm(upper limit).3. Axle of the wheel is also repaired here. Generally the diameter of

the axle doesn’t reduces.4. Axle is generally condemned because of permanent cracks and

deformity or corrosion.5. Wheel in the range of 915mm-837mm are further machined in CNC

machine or Lathe machine which gives it a perfect finish and removes all the deformity.

6. Ultra sound is carried out to see if there are any cracks in the wheels or axle.

7. After all the processes die and magna flux test is carried out on wheels, axles and bearing to check the cracks less than 2mm under U.V rays.

8. Condemned wheels are replaced by new wheels.9. Axle is also machined on axle turning CNC machine.10. After all the inspection and repair work the wheel, bearing and axle are assembled together and shifted towards the bogie shop for being assembled in the bogie.

BEARING

Body Repair ShopThe entire body of the coach shell is repaired here.

In this shop overall structure of the coach body is repaired by simple electrical arc welding and MIG welding, since main component of the body shell is made of iron and steel.

The entire coach body including structural members is subjected to inspection and replacement of corroded members giving necessary anti-corrosive treatment to the components.

The lower coach portion of the is removed here because it gets corroded due to rain and moisture which is replaced here.

This shop is supported by SHELL COMPONENT SHOP.

Paint ShopIn this shop the entire parts of the coach gets painted.

The coach shell is given a new look by complete painting.

Lettering work is done by screen printing process

The work of FRP tissue on the trough floor is also done in this shop.

It is a 7 day scheduled process.

Furnishing ShopAs the name depicts, the furnishing work of coaches is done here.

Basic passenger amenities are installed here like mirror, berths, windows, seats, PVC flooring and testing of plumbing arrangements.

Entire electrical fitting is done here. Lights and fans fitments, Air-conditioning, brake fitment is done here.

Air Brake System

FINAL SHOPThis is the final shop where MLR process of the coach ends. In this shop fully furnished coach comes from the furnishing shop and bogie from the bogie shop.

Both are assembled here.

The coach is lowered on overhauled bogies. Final adjustments and tests of out-going coaches including NTXR examination is done by pit inspection facility available in the shop.

If anything is found incomplete or incorrect, the repair work is carried out by sending it to the respective shop.

After full inspection and testing, coach is sent out of the workshop.