ACKNOWLEDGEMENT

I owe a great many thanks to a great many people who helped and supported me during the entire project.

I , , the student of Mechanical Engineering DEPARTMENT, , am extremely grateful to “ COACH REHABILITATION WORKSHOP , BHOPAL” for the confidence bestowed in me .

I express my thanks to the Principal of, JAI NARAIN COLLEGE OF TECHNOLOGY, for extending his support.

My deep sense of gratitude to PRINCIPAL, TECHNICAL TRAINING CENTRE, COACH REHABILITATION WORKSHOP (CRWS), BHOPAL for their support and guidance. Thanks and appreciation to the helpful people at different workshops in COACH REHABILITAION WORKSHOP , BHOPAL for their kind support.

My deepest thanks to Lecturer, the Guide of the project for guiding and correcting various documents of mine with attention and care.

DECLARATION

I, , student of B.E. (Mechanical Engineering) hereby declare that the study of “ COACH REHABILITAION WORKSHOP BHOPAL ’’. The work has been carried out under the guidance of helpful people at different workshops in COACH REHABILITAION WORKSHOP for their kind support.

PREFACE

Summer Intership Project is a golden opportunity for any B.E. student to know all the aspects of industry concern. The main purpose of Summer Internship Project is to develop a strong moral and confidence in the student . Summer Intership Project plays a very vital role in our life and it proves to be very helpful in providing accessibility to practical knowledge and to live as a professionals.

In Summer Internship Project , every student should go in-depth of the theoretical and analytical aspect of his\her topic. It results in better understanding about a particular field.

I have got a better chance to complete my four weeks intership at “COACH REABILITATION WORKSOP, BHOPAL’’ which has built a great confidence in me .

CONTENTS

CHAPTERS

CHAPTER 1. Introduction Company Profile

CHAPTER 2. Services offered by companyFeaturesLayout

CHAPTER 3.Workshops , layouts and its applications.Pocket yardLifting Shop Stripping and PCR ShopBogie ShopWheel and baring shop Body repair shopCarpentry shopSell Component sop AIR BRAKE shopPaint shop Furnishing shopFinal shop

INDIAN RAILWAYS

Indian Railways is an Indian state-owned enterprise, owned and operated by the Government of India through the Ministry of Railways.

It is one of the world's largest railway networks comprising 115,000 km (71,000 mi) of track over a route of 65,436 km (40,660 mi) and 7,172 stations.

In 2013–14, IR carried 8,425 million passenger’s annually or more than 23 million passengers daily (roughly half of which were suburban passengers) and 1050.18 million tons of freight in the year. 

Railways were first introduced to India in the year 1853 from   Bombay   to   Thane .

In 1951 the systems were nationalised as one unit, the Indian Railways, becoming one of the largest networks in the world.

IR operates both long distance   and   suburban rail systems   on a   multi-gauge   network of   broad ,   metre   and   narrow   gauges . It also owns   locomotive   and   coach   production facilities at several places in India and are assigned codes identifying .

COACH REHABILITATION WORKSHOP BHOPAL

Coach Rehabilitation Workshop is located at Nishatpura area, in the city of lakes Bhopal, which is the political capital of the State of Madhya Pradesh. The workshop is situated at a distance of 2 Km from the Bhopal Railway station.

The Workshop was started in year 1989 at a project cost of approx Rs.64.97 Cr for Mid Life Rehabilitation (MLR) of Indian Railway Coaches. It has completed more than 20 years of service to the Nation. CRWS has so far turned out 6905 coaches including 420 AC coaches. During the year 2010-11 it has achieved best ever production of 571 coaches.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. Overhauling activities includes heavy corrosion repair to the shell body and under frame, renewal/repair on account of furnishing, train lighting & painting. This activity results in savings in repair cost in subsequent years of serviceof coaches apart from providing improved customer satisfaction for passengers.

The quality of coaches coming out of CRWS has had excellent reputation over the years and now it is being treated as benchmark for all other workshops planning overhaul activity. CRWS's quality,environmentand occupational health & safety management systems continue to be certified to ISO 9001, 14001 & OHSAS 18000. The workshop layout is based onU-flow with majority movement being on dummy bogies on merry go round system.

Total budget allotment of the shop is around Rs.121 Crores for a year. The shop functions out of budget provisions from railway board in the form of Rolling stock program.The committed workforce of the workshop has carried out many innovative system improvements over the years including in-housedevelopment of RFID based gate attendance & incentive calculation system etc. The shop has outsourced many activities over the years including grit blasting of outer surface of shell, sand blasting of bogie flames, retro fitment of air brakes, over hauling of air brakes cylinders,screen of coach number printing etc.

A Regional Welding Institute for comprehensive training of welders of various railways has been set up and various modules are being operated in workshop premises.

RAILWAY ZONES

The Indian Railways is divided into zones, which are further sub-divided into divisions, each having a divisional headquarters. There are a total of sixty-nine divisions.[1]

Each of the divisions, is headed by a Divisional Railway Manager (DRM) who reports to the General Manager (GM) of the zone. A DRM can be appointed from any services of Indian Railway, Indian Administrative Service (IAS) and Indian Revenue Service (IRS) for the tenure of 3 years but it can be exceeded on the recommendation of Railway Board. Divisional officers heading all departments viz. engineering, mechanical, electrical, signal and telecommunication, accounts, personnel, operating, commercial, safety, medical, security branches report to the Divisional Railway Manager. The DRM is assisted by one or two Additional Divisional Railway Managers (ADRM) in the working of the division.

There are 16 zones and the 68 divisions are listed below:[2]

Sl. No

Name of the Railway zone

Abbr.

Route length(in Km)

Headquarters Divisions

1. Central Railway CR 3905 Mumbai

Mumbai,[3] Bhusawal,[4] Pune,[5] Solapur,[6]

Nagpur [7]

2.East Central Railway

ECR 3628 HajipurDanapur,[8] Dhanbad, Mughalsarai, Samastipur,[9] Sonpur

3.East Coast Railway

ECoR 2572 Bhubaneswar Khurda Road, Sambalpur, Waltair [10]

4. Eastern Railway ER 2414 Kolkata Howrah, Sealdah,

Asansol, Malda

5.North Central Railway

NCR 3151 Allahabad Allahabad,[11] Agra, Jhansi

6.North Eastern Railway

NER 3667 Gorakhpur Izzatnagar, Lucknow, Varanasi

7.North Western Railway

NWR 5459 Jaipur Jaipur,[12] Ajmer, Bikaner, Jodhpur

8.Northeast Frontier Railway

NFR 3907 GuwahatiAlipurduar, Katihar, Rangia, Lumding, Tinsukia

9. Northern Railway NR 6968 Delhi

Delhi,[13] Ambala,[14]

Firozpur,[15] Lucknow,[16] Moradabad [17]

Sl. No

Name of the Railway zone

Abbr.

Route length(in Km)

Headquarters Divisions

10.South Central Railway

SCR 5803 Secunderabad

Secunderabad,[18]

Vijayawada, Hyderabad, Guntakal, Guntur, Nanded

11.

South East Central Railway

SECR 2447 Bilaspur Bilaspur, Raipur

12.South Eastern Railway

SER 2631 Kolkata Adra, Chakradharpur, Kharagpur, Ranchi

13.South Western Railway

SWR 3177 Hubli Hubli, Bangalore, Mysore

14. Southern Railway SR 5098 Chennai

Chennai,[19]

Tiruchirappalli,[20]

Madurai,[21] Palakkad,[22] Salem,[23]

Thiruvananthapuram [24 ]

15.West Central Railway

WCR 2965 Jabalpur Jabalpur, Bhopal, Kota

16. Western Railway WR 6182 Mumbai

Mumbai Central, Ratlam, Ahmedabad, Rajkot, Bhavnagar, Vadodara

FEATURES OF MLR DONE IN CRWS

It as been estimated by work study that rehabilitation work content is nearly 4 times that of normal POH . Normal POH does not include major corrosion repairsAnd takes about 2500 man-hours. Mid life rehabilitation includes heavy corrosion repair and complete refurbishing which takes about 10000 man ours . At present this workshop is capable of undertaking any type of ICF coach and BEML coach with ICF bogies.

Te underlying principle of MLR is to give ‘As new’ condition to the coach at its mid life i.ewhen it is 2-5 years of age.Unlike in POH,the coach is completely stripped,heavy corroded ares attended to,fibre glass tissue re-laid/re-painted , necessary modifications carried out and new furnishing is provided. It can be seen that wile corrosion repair is minimal attended to , during POH , in MLR it is completely attended to.

Various modifications prscribed by Railway Board/RDSO improving the performance of coaches,are being implemented in this workshop.Some of them are:-Laying of FRP tissue on troug floor.Provision of stainless steel inlays in lavatories.Retro-fitment of air brakesPop riveting of mirror frames.The roller bearing section as been improved and all recommendations of COFMOW report have been implemented.

What constitutes the CRWS ?1. POCKET YARD 2. LIFTING SHOP 3. BOGEY SHOP 4. WHEEL SHOP 5. PCR SHOP6. BODY SHOP

7. FURNISHING SHOP 8. CARPENTRY SHOP 9. PAINT SHOP 10. FINAL SHOP

POCKET YARD The process of MLR (MID LIFE REHABILITAION) starts with the entry of the railway coach in pocket yard.

In pocket yard the coach comes for inspection, whether it is fit for the MLR or not. Several inspection are done for this purpose.

Since only the coaches which is at their mid life (e.g. 12-15 years) are selected for rehabilitation, for e.g. in 2014 the coaches built between 1998 to 2003 are select for MLR.

In pocket yard the coaches are com by railway line Bhopal station. Here they are kept for inspections.

Some inspection are as follows :

1. Inspection of the type of coach.2. Inspection of the year of manufacturing of coach.3. Inspection of the defects in coach.4. Inspection of corrosion in coach.5. Inspection of damaged part of coach.

These are some basic inspection done selecting the coach for MLR.

LIFTING BAYAt the lifting bay, where it is simply lifted on a high lifting machine.In this shop coaches are lifted to remove bogies (the part of coach contain wheels and brake) for repairs and dummy bogies (temporary bogies with temporary connections) are provided for internal movement within the workshop.In this shop the bogies are removed from coach by disconnecting the centre pivot and two side bearer provided in each bogie.( a coach has 2 bogies)Examination and repair of under-frame including centre pivot and side bearers are done in this shop.The lifting shop is just behind the wheels and bogie sop and also connected to the stripping and P.C.R shop and carpentry shop. After the removal of the bogies they are sent to bogie shop and then wheels and bearing are removed from the bogie and shifted to wheel shop.And the coach is shifted to STRIPPING and PCR SHOP for further repair.

STRIPPING & PCR SHOPAs clear from its name “ STRIPPING and PCR SHOP” , the work of stripping of the internal as well as external part of coach body is done in this shop and also the checking of corrosion affected area is done here.In this shop internal components and fittings are stripped off to get bare shell for corrosion repairs . Wall panels and flooring is removed. Cutting of body side panels by “air plasma cutting” is done in this shop.In this shop the outer covering of coach body is removed and the inner shell components are made visible for corrosion treatment.The coach body is cut by modern technique known as Plasma Cutting for better and smooth cutting work without affecting any other part. The cutting of side panel is done in step by step process. First it is cut to height of 500mm from bottom to top and if symptoms of corrosion are found above this. Pre-inspection of coaches is most essential aspect for identifying onset of corrosion. It must be done after dismantling under slung components such as battery box, vaccum cylinder, vaccum chamber , brake shaft and electrical panel . All the pockets of under gear, head stocks and old welding heads on sale bar surfaces must be cleaned thoroughly of mud etc. to have clear visibility of cracks and corrosion.After the cutting of the body panel the internal fitting of floor, lavatory, seats, births, doors, windows are done here. After this all the mechanical fitting are send to carpentry shop for repair and the coach is sent to the body repair shop for further repair of the coach body frame.

CARPENTRY SHOPAfter the removal of all mechanical fitting in per shop they come in carpentry shop for repair.All internal mechanical fitting and furnishings including berths and seats water tanks are repaired in this shop.

The main section in this shop are :1. PLUMBING SECTION: In this section the all the fitting used in plumbing work in coach is repaired like water tank, housings, pipelines etc.For repair to tank TIG WELDING is done. And leakage tests is done for tanks at 0.35kg/sq.cm2. DOOR SECTION: In this section the doors are repaired by simple welding and which is removed from the coach.3. SHUTTER SECTION: In this section the shutters of window is repaired by simple welding and which is removed from the coach.The equalizing device used for lifting window is also repaired in this section.4. CARPENTRY SECTION 1: In this section the old seats and births are come and the old material is removed and structure is also removed.5. CARPENTRY SECTION 2: In this stop the remoulding of seats and birth is done. 6. TRIMMING SECTION: In this section the furnishing of carpentry is done.

BODY REPAIR SHOPAs clear from its name “Body Repair Shop”, the entire body of coach shell is repaired here.

The entire coach body including members is subjected to inspection and replacement of corroded members giving necessary anti-corrosive treatments to the components .RSP modification including provision of UIC Vestibules are also done in this shop.

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

In this shop a large number of coaches are repaired simultaneously. This shop is supported by “SHELL COMPONENT SHOP”.

SHELL COMPONENT SHOP

The body repair shop does not manufactured any required part that the reason shell component shop is set up.

Component required for the fitment in the coach sell are being manufactured from the raw material (mainly corrosion resistant steel). It is a feeder shop for body repair shop.

PAINT SHOPIn this shop the entire parts of the coaches get painted.The coach shell is given a new look by complete painting (A-SCHEDULE is undertaken). LETTERING WORK on exterior as well as coach interior is done by screen printing process. The work of laying FRP tissue on the trough floor is also done in this sop. Air-brake retro fitment work is done in this shop.In this shop the paint work is done by hand or by the help of the automatic painting machine. Here two-three layer of paint along wit primer and anti-corrosive is applied on the body of the coach.A-SCHEDULED IS 8662/2004

1st day: As per need remove old paint wit scraper.

2nd day: Put primer on the old paint and on ten e panel fitted and also to apply first coat of putty (primer IS 2074/1992), PUTTY IS 5083/1988.

3rd day: Second coat of putty and filler coat( filler IS 118/1983)

4th day: Coating of t anticorrosion paper.

5th day: Anti-corrosive rd oxide paint and first coat of the primary paint (blue).

6th day: Second coat of the primary paint (blue).

7th day: Finishing of work.

FURNISING SHOP

Aesthetic look, comfort and safety are very much essential for pleasant journey. Furnishing division takes care of the above by furnishing the interior of the coaches.

All passenger amenities fitting and internal components (both mechanical and electrical) in the coach are replaced/refitted. The work of PVC flooring and testing of plumbing in lavatories are done in this shop.

As clear from its name all the finishing work is done in this shop. All mechanical parts like seats ,births, doors, windows and all other carpentry products are fitted in this shop. More over the entry electrical fitting is done and tested here.

Furnishing of coaches is done in stages , viz.

GRIT BLASTING, Painting in automatic paint booths , drying in ovens , lettering .

Flooring , wiring , paneling on side walls , window fixing , partition paneling , floor moulding , lights & fans fixing , seats , berths and racks fixing , air-conditioning where required , brake fitment and buffer height adjustment.

BOGIE SHOP

Bogies are the part on which the whole body of t coach is mounted, it also help the coach to run on the track and also help in stopping of coach.

In this bogie shop the bog are come from the lifting bay and then the bogie is stripped of completely and the wheels and bearing are shifted toward the wheel and bearing shop respectively.

The running and brake gar provided in bogies are completely stripped, cleaned , inspected and refitted.

The bogie frames are shot blasted. Bogies are modified and provided wit brake gearing for bogie-mounted air-brake system.

The main work done in bogie shop is repairing of structure of body it is over corroded than it is rejected immediately.

In bogie shop went e bogie comes, it is visually inspected by inspector than the dimension of bogie is checked by gauges if the dimension is correct if it shift for further repair otherwise the dimension is corrected by heating and cutting and final repairing work is done by welding . And then the bogie become reusable.

WHEEL & BEARING SHOP

After removal of the wheel from the bogie shop, they come in wheel shop. Here the inspection of wheel is done by checking its diameter (upper limit 915mm and lower 837mm below this the wheel is rejected).

If the wheel diameter is between upper and lower limit its if further turned by CNC machine or lathe machine.

Here the ale of wheel is also repaired for this purpose separate axle turning CNC and late is used.

After the repair of both wheels and axles they are again assembled wit the help of the wheel press machine.

In this shop the bearing (roller bearings) of wheel is also checked but not repaired. A separate shop inside wheel shop is setup for checking of the bearing , several test like magna flux test is done by magma flux testing machine for checking the crack of less tan 2mm and U.V. lamp is used to s crack clearly.

After all the inspection and repair the wheel bearing and axle is assembled together and shifted toward the bogie shop for being assembled in bogie.

In this shop the work of over all wheel assembly is done. Here several machines are provided for repairing of different component of the wheel and axle assembly.

If any components like wheel, axle, bearing etc are not repaired they are also change here by the new one.

FINAL SHOPThis is the final shop were the MLR process of the coach ends. In this shop fully furnished coach come through the furnishing shop and bogie from bogie shop and both are assembled here (during entire MLR process coach is temporary set on dummy bogie). And coach becomes ready for use again. The coach body is lowered on overhauled bogies. Final adjustments as tests/inspection of out-going coaches including NTXR examination is undertaken in the final shop, which has pit inspection facility.In this shop several inspection on shop is done by visual inspection if the coach complete the inspection or test only than it is allow to go for further use otherwise it is again return for repair in the respective shop where defect is found like if paint is not proper it is further send to paint sop for painting.In this shop after the completion of inspection and various test the coach is finally allow to go for further use.In other word we can say that it is the final stage of M.L.R PROCESS where the COACH GET REHABILITATED COMPLETELY and ALLOW TO USE FOR SEVERAL MORE YEARS.