Indian railway ajmer

  • View

  • Download

Embed Size (px)



Seminar Report On

Loco workshop of railway





Submitted in partial fulfilment of theRequirements for the degree








This is certify that this report on Practical Training taken at locomotive workshop of NORTHAN WESTERN RAILWAYS is submitted by (AKASH SHARMA) to the Department of Mechanical Engineering, Pacific Institute of Technology, Udaipur, for the award of the degree in B.Tech Mechanical Engineering is a bonafied record of work carried out by him/her. The contents of this Seminar Report, in full or in parts have not been submitted to any other Institute or University for the award of any degree or diploma.

Mr. Ahsan HabibSeminar Coordinator Head of Department


Inspiration and motivation have always played a key role in the success of any venture.

Success in such comprehensive report cant be achieved single handed. It is the team effort that sail the ship to the coast. So I would like to express my sincere thanks to my mentor (Mr._______). It gives me immense pleasure to express my gratitude to the department of Mechanical Engineering for their prudent response in course of completing my training report. I am highly indebted to, (MR._______) and (MR. ________), their guidance and whole hearted inspiration; it has been of the greatest help in bringing out the work in the present shape. The direction, advice, discussion and constant encouragement given by them has been so helpful in completing the work successfully.

This training wasnt possible if HOD of mechanical department Mr. Ahsan Habib Wouldnt have allowed us in the first place, so thanks to him as well.



ChapterPage NoINTRODUCTION101.) ORGANSATION STRUCTURE111.1) Zones of Indian Railways121.2) Departments142.) NORTH WESTERN RAILWAY152.1) Facts and Other Statistics152.2) Brief Outline of the Divisions172.2.1) Jaipur Division172.2.2) Bikaner Division172.2.3) Jodhpur Division172.2.4) Ajmer Division173.) WHEELS193.1) Wheels testing and machine203.2) Axial journal testing lathes203.3) Hydraulic wheel presses with a facility of mounting213.4) Vertical turning lathe214.) MACHINE SHOP224.1) Manually operated machine234.1.1) Drilling section234.1.2) Center lathe section234.1.3) Shaper244.1.4) Slotter245.) BRAKING SYSTEM255.1) Air Brake System255.1.1) Brake container255.1.2) Connections to the Container275.1.3) Brake Application275.1.4) Brake Release275.2) Bogie Brake Equipment275.2.1) Brake Caliper Units285.2.1.1) Working principle28

15.2.2) Brake Cylinders295.2.3) Brake Discs295.2.4) Brake Shoe305.3) Brake Rigging System305.4) Wheel Slide Protection Equipment316.) BOGIE SHOP326.1) Introduction to BCNHL wagon326.2) Welding336.2.1) Arc welding346.2.1.1) Arc welding circuit346.2.1.2) Defects of arc welding357.) SPRING SHOP377.1) Spring treatment377.1.1) Visual and magnetic crack detection377.2) Spring scraping387.3) Various reasons of spring failure387.4) D buckling388.) DIESAL SECTION398.1) Turbo supercharger408.1.1)Turbo supercharger principle408.2) Turbo run-down test408.3) Rotor balance machine418.4) Advantage of super charged engines418.5) Defects in turbocharger419.) FUEL OIL SYSTEM429.1) Fuel oil system429.1.1) Fuel injection pump439.2) Spray pattern449.3) Spray pressure4410.) CYLINDER HEAD4510.1) Component of cylinder head4510.2) Maintenance and inspection4610.2.1) Cleaning4610.2.2) Crack inspection46

10.2.3) Hydraulic test4610.2.4) Dimensional check4610.2.5) Straightness of valve stem4610.2.6) Blow by test4611.) SCHEDULE EXAMINATION4711.1) Minor schedule4711.2.1) Trip-14811.2.2) Trip-24811.2.3) Mounthly-2 schedule4811.2.4) Major schedules4912.) CONCLUSION5012.1) Improvements suggested to company5012.2) Findings50



Table No.Name of TablePage No.

Table 1.1)List of Zones of Indian Railways13

Table 1.2)List of Departments14

Table 2.1)List of Ajmer statistics18

Table 3.1)List of wheels dimension19

Table 3.2)List of wheels19

Table 7.1)Spring failure rate37


Figure No.Name of FigurePage No.

Fig 1.1)Indian railway logo10

Fig 1.2)Zones Map12

Fig 2.1 )Logo of North Western Railway15

Fig 2.2)Map of North Western Railway16

Fig 3.1)Wheels19

Fig 3.2)Axial lathe20

Fig 3.3)Hydraulic wheel press21

Fig 3.4)Vertical turning lathe21

Fig 4.1)Computer numerical control22

Fig 4.2)Drilling machine23

Fig 4.3)Lathe machine23

Fig 4.4)Shaper machine24

Fig 4.5)Slotter machine24

Fig 5.1)Brake equipment for passenger coach25

Fig 5.2)Brake equipment panel26

Fig 5.3)Break equipment for generator coach26

Fig 5.4)Brake caliper unit28

Fig 5.5)Brake Cylinders and Callipers29

Fig 5.6)Axle Mounted and Wheel mounted brake disc30

Fig 5.7)Diagram showing breake rigging pressure31

Fig 5.8)Speed sensor and phonic wheel31

Fig 6.1)BCNHL wagon32

Fig 6.2)Flow process of BCNHL wagon33

Fig 6.3)Welding process34

Fig 6.4)Porosity35

Fig 6.5)Spatter35

Fig 6.6)Fixed manipulator36

Fig 7.1)Spring37

Fig 7.3)D buckling machine38

Fig 8.1)Turbocharger39

Fig 8.2)Impeller40

Fig 9.1)Fuel oil system42

Fig 9.2)Fuel injection pump43

Fig 9.3)Fuel injection pump testing44

Fig10.1)Cylinder head45


(Fig 1.1 Indian railway logo)

"Lifeline of the Nation" Type: Public sector undertaking Reporting mark: IR Industry: Railways Founded: April 16, 1853 Headquarters: New Delhi, India Area served: India Chairman: Arunendra Kumar Services: Passenger railways: Freight services: Parcel carrier: Catering and Tourism Services: Parking lot operations: Other related services Track gauge: 1,676 mm (5 ft 6 in): 1,000 mm (3 ft 3 38 in): 762 mm (2 ft 6 in): 610 mm (2 ft) Electrification: 23,541 kilometers (14,628 mi) Length: 65,000 kilometers (40,000 mi) Revenue: 1256.8 billion (US$21 billion) Net income: 104.1 billion (US$1.7 billion) Owner(s): Government of India (100%) Employees: 2.2 million (2012) Parent: Ministry of Railways through Railway Board (India) Zones: 17 Railway Zones Website:


Indian Railways (reporting mark IR) 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 65,000 km (40,000 mi) and 7,500 stations. In 2011, IR carried over 8,900 million passengers annually or more than 24 million passengers daily (roughly half of which were suburban passengers) and 2.8 million tons of freight daily. In 20112012 Indian Railways had revenues of 1119848.9 million (US$19 billion) which consists of 696759.7 million (US$12 billion) from freight and 286455.2 million (US$4.8 billion) from passengers tickets.

Railways were first introduced to India in 1853 from Bombay to Thane. In 1951 the systems were nationalized 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, meter and narrow gauges. It also owns locomotive and coach production facilities at several places in India and are assigned codes identifying their gauge, kind of power and type of operation. Its operations cover twenty nine states and seven union territories and also provide limited international services to Nepal, Bangladesh and Pakistan.

Indian Railways is the world's ninth largest commercial or utility employer, by number of employees, with over 1.4 million employees. As for rolling stock, IR holds over 239,281 Freight Wagons, 59,713 Passenger Coaches and 9,549 Locomotives (43 steam, 5,197 diesel and 4,309 electric locomotives).

The trains have a 5 digit numbering system as the Indian Railways runs about 10,000 trains daily. As of 31 March 2013, 23,541 km (14,628 mi) (36%) of the total 65,000 km (40,000 mi) route length was electrified. Since 1960.

On 23 April 2014, Indian Railways introduced a mobile app system to track train schedules.The first railway on Indian sub-continent ran over a stretch of 21 miles from Bombay to Thane. The idea of a railway to connect Bombay with Thane, Kalyan and with the Thal and Bhore Ghats inclines first occurred to Mr. George Clark, the Chief Engineer of the Bombay Government, during a visit to Bhandup in 1843.Indian Railways runs around 11,000 trains every day, of which 7,000 are passenger trains.

191.1 Zones of Indian RailwaysIndian Railways is divided into several zones, which are further sub-divided into divisions. The number of zones in Indian Railways increased from six to eight in 1951, nine in 1952 and sixteen in 2003 and now seventeen. Each zonal railway is made up of a certain number of divisions, each having a divisional headquarters. There are a total of sixty-nine divisions.Each of the seventeen zones is headed by a general manager who reports directly to the Railway Board. The zones are further divided into divisions under the control of divi