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INDUSTRIAL TRAINING REPORT
AT
MECHANICAL WORKSHOP
NORTH EASTERN RAILWAYS, GORAKHPUR
FOR COURSE -
B.TECH. (5th
SEMESTER)
PRODUCTION AND INDUSTRIAL ENGINEERING
PI-319 VOCATIONAL TRAINING REPORT
SUBMITTED BY -
PRAVEEN KUMAR UPADHYAY
SUBMITTED TO –
Prof. V.S.N. Reddy
Dept. Of Mechanical Engineering, N.I.T.KURUKSHETRA

ACKNOWLEDGEMENT
Mechanical workshop of north eastern railway, Gorakhpur is a well-
known public sector industry. I am deeply grateful to Chief Workshop
Manager, Who gave me a chance to have an insight of the vocational
training of four weeks.
By seeing the good management of the plant, I learnt a lesson three D’s
Discipline, Determination and Devotion .I also grasp an idea of state-of-
the-art technology and plant.
I would like to take this opportunity to express my profound sense of
gratitude and sincere thanks to Mr. ANIRUDH SINGH for being helpful
and a great source of inspiration. His keen interest and constant
encouragement gave me the confidence to complete my Industrial
Training successfully. I wish to extend our sincere thanks for their

excellent guidance and suggestions for the successful completion of my
training.
LIST OF CONTENT
1. INTRODUCTION TO GORAKHPUR RAILWAY WORKSHOP
2. MACHINE SHOP
3. SMITHY AND CARRIAGE COMPONENT SHOP
4. HEAT TREATMENT SHOP
5. SPRING SHOP
6. WHEEL AXLE SHOP
7. BOGIE SHOP
8. BRAKE SHOP
9. SHELL SHOP
10. FURNISHING SHOP
10.1 PAINT SHOP
NAME PRAVEEN KUMAR UPADHYAY
COURSE B.Tech.
COLLEGE National Institute Of Technology,
Kurukshetra
ROLL NO. 11610758
BRANCH PRODUCTION AND INDUSTRIAL
ENGINEERING

10.2 SEAT SHOP
10.3 AC-SHOP
10.4 WATER TANK SHOP
11. MATERIAL HANDLING SYSTEM
12. OBSERVATION AND REPORT
13. REFERENCES
ABOUT GORAKHPUR MECHANICAL WORKSHOP
Gorakhpur workshop was established in 1903 for repair and overhauling
of MG steam locomotives, coaches and wagons. Due to gauge conversion
from MG to BG, POH activity of 50 BG coaches /month was started in
Sep 1984.The POH of MG coaches was also stopped from January
2002.At present, this workshop is mainly carrying out POH of BG AC
and NON-AC coaches in number 180 per months. Capacity augmentation
and modernization project Phase-1 (costing Rs.22.7 crore) and Phase -2
(costing Rs.18 cr.) has been sanctioned and are under progress.
STATISTICS AND SPECIFICATION
1. No of officers -19.
2. No of supervisors-378.
3. On roll strength- 5282.
4. Total area covered-29.8 Hectare.
5. Covered area-12.6 Hectare.
6. Township area Gorakhpur.
7. Power consumption- 208662 KWH.

In Mechanical workshop there are various shops dedicated to meet the
requirements. Every shops are provided to carry out the different
manufacturing processes that are required in overhauling processes. The
various shops are listed below. To get the desired efficiency the
supervisors and workers are given with a specific shop to perform the
machining and non-machining processes.
1. Machine Shop
2. Shell Shop
3. Heat Treatment Shop
4. Spring Shop
5. Brake Shop
6. Air Conditioning Shop
7. Wheel Shop
8. Bogie Shop
9. Paint Shop
A Creative Description of the Make In India Program at
NER Workshop

Layout of Workshop published in
2018
Machine shop
Description
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 either performed manually or on
automatic machines.
Machines are two types...
1. Automatic
2. Manual
There are three types of automatic machine.
1. Numerical control
2. Computer numerical control
3. Direct numerical control machine

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.
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.
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.

Theses sections are-
1. Capstan and turret lathe section
2. Milling section
3. Center lathe section
4. Drilling section
5. Shaper and Slotter section
6. Heavy machine section
CAPSTAN AND TURRET LATHE SECTION
The turret lathe is a form of metalworking lathe that is used for repetitive
production of duplicate parts, which by the nature of their cutting process
are usually interchangeable. It evolved from earlier lathes with the
addition of the turret, which is an index able tool-holder that allows
multiple cutting operations to be performed, each with a different cutting
tool, in easy, rapid succession, with no need for the operator to perform
set-up tasks in between, such as installing or uninstalling tools, nor to
control the toolpath.
A Vertical Turret Lathe to dig the Bore of Wheel

A Herbert Turret Lathe machine to produce Plug stopper for
wheels
The latter is due to the toolpath's being controlled by the machine, either
in jig-like fashion, via the mechanical limits placed on it by the turret's
slide and stops, or via electronically-directed servo mechanisms for
computer numerical control lathes.
A capstan machine is a processing machine used to make the same parts
again and again. The cutting bits are mounted on a rotatable turret known
as a capstan, which permits the client to rapidly change the introduction
of the bits for slicing without needing to take off the first bit and afterward
mount the second. A bit of crude material, off and on again known as a
clear, is mounted into the capstan machine and is then spun at high
velocity.
MILLING SECTION
Milling is the machining process of using rotary cutters to remove
material from a work piece by advancing (or feeding) in a direction at an
angle with the axis of the tool. It covers a wide variety of different

operations and machines, on scales from small individual parts to large,
heavy-duty gang milling operations.
It is one of the most commonly used processes in industry and machine
shops today for machining parts to precise sizes and shapes.
A Horizontal Linear moving Hobbing machine to produce
V-Locks
In the vertical mill the spindle axis is vertically oriented. Milling cutters
are held in the spindle and rotate on its axis. The spindle can generally be
extended (or the table can be raised/lowered, giving the same effect),
allowing plunge cuts and drilling. There are two subcategories of vertical
mills: the bed mill and the turret mill.
 A turret mill has a stationary spindle and the table is moved both
perpendicular and parallel to the spindle axis to accomplish cutting.
The most common example of this type is the Bridgeport, described
below. Turret mills often have a quill which allows the milling cutter
to be raised and lowered in a manner similar to a drill press. This
type of machine provides two methods of cutting in the vertical (Z)
direction: by raising or lowering the quill, and by moving the knee.
 In the bed mill , however, the table moves only perpendicular to the
spindle's axis, while the spindle itself moves parallel to its own axis.

A horizontal Shaping machine to produce lever hold for the
Gas Blast cylinders
CENTER LATHE SECTION
Heavier lathes are provided in this section. All the lathes have four jaws
chuck for better holding centering is done either manually or with the help
of universal scriber. All kinds of turning are performed here. Parting off
is other major operation done.

Worker making hexagonal headed and square headed bolts on
Centre Lathe
DRILLING SECTION
Drilling operation is carried out here. A large for the operation .To
complete the operation faster a few gauge milling machine are also
provided. Cutting fluid is sometimes used to ease this problem and to
prolong the tool's life by cooling and lubricating the tip and chip flow.
Coolant may be introduced via holes through the drill shank, which is
common when using a gun drill. When cutting aluminium in particular,
cutting fluid helps ensure a smooth and accurate hole while preventing the
metal from grabbing the drill bit in the process of drilling the hole. In
computer numerical control(CNC) machine tools a process called peck
drilling, or interrupted cut drilling, is used to keep swarf from
detrimentally building up. Peck drilling involves plunging the drill part
way through the workpiece, no more than five times the diameter of the
drill, and then retracting it to the surface. This is repeated until the hole is
finished. A modified form of this process, called high speed peck drilling
or chip breaking, only retracts the drill slightly.

A Vertical Drilling machine to drill holes in the Al-Based-
Electric nose and caps
A Gang-Drilling machine to drill holes in the Bolts,
Wires or Pipes
SHAPER AND SLOTTER SECTION

(A) SHAPER
The machine is also called horizontal shaping machine. It works on quick-
return mechanism .The arm of shaper reciprocating horizontally. The
cutting take place only in the forward stroke. The bed of the machine is
fixed and the tool reciprocating. Shaping, Planning, Grooving etc. are
performed by this machine.
(B) SLOTTER
The slotter 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.
(C) N.C.BORING
By this boring machine, various different operations can be done such as
drilling machine etc. The depth of cut and the feed is controlled by
pushing the button of control panel. The fig.is displayed while machine,
the work table rotates and the tool is fixed.
(D) PLANER
A planer is a type of metal working machine tool that uses linear relative
motion between the work piece and a single-point cutting tool to cut the
work piece.
A CNC used for the production of the Axles with required
dimensions
SMITHY AND CARRIAGE COMPONENT SHOP

Smithy Shop
 A smithy’s work involves heating of a metal stock to a desired
temperature, enable it to obtain sufficient plasticity, followed by the
operations like hammering, bending, pressing etc., to give it the
desired shape. This is known as forging.
 The above operations can either be carried out by hand hammering,
by power hammers, or by forging machines.
 Hand forging is the term used for the process when it is done by
hand tools. Similarly, forging done with the help of power hammers
is known as power forging, when carried out by means of drop
hammers as drop forging, and when by forging machines as machine
forging.
 Applying pressure for shaping the metal, the primary requirement
always is to heat the metal to a definite temperature to bring in into
the plastic state.

Activities of Smithy Shop
This shop is manufacturing following items:-
1. Cast Iron rollers of various sizes for FBWP/JSG,
2. C.I. Chair Plate for SEJs
3. C.I. Brake blocks for T.T. Organs.
4. Special Type of C.I. Bearing plates
5. C.I. Blocks for CMS crossings.
6. Gunmetal bearings for Push Trolley
7. Rail tongs,
8. ‘U’ clamps for unloading of welded panels from Modified
BRNs
9. Components for Push Trolley
10. Fittings for diamond switch of fan shaped lay out.
The Smith Shop should be divided into the following three sub-shops:
 Forge.
 General Smithy.

 Bolt Shop.
The expenditure incurred in each of these sub-shops should be allocated
as for the foundries under the following main headings:—
 Cost of Metal.
 Direct labour charges.
 Oncost.
In the Forge, General Smithy and Bolt sub-shops, the metal and direct
labour charges should be booked to individual work orders issued by the
Production Office, or to revenue maintenance standing work orders. The
charges which cannot be directly allocated to any particular work order
should be booked against the work orders for shop oncost, within the
respective sub-shops, and distributed in the usual way over the jobs done
during the month, in proportion to the productive labour booked against
each.
Labour—In the Smithy, more than one man is often employed on any
one particular job done and the Job Card for squad work (W. 507) is best
used for recording the daily labour charges incurred on various jobs.
Materials—Different kinds of steel or iron are required for use in the
Smithy from time to time. It is essential that there is available a sufficient
stock equal to one or one and a half month's demand of steel and iron in
the shop. As in the case of the foundries, the Store-keeping Service should
be rendered by the Stores Department.
Shop Oncost within the Smith Shop—The charges in connection with
heating, fitting pickling, annealing, general labour and transport cannot be
allocated to any particular job and should, therefore, be accounted for as
shop oncost.
Metal Losses—The metal loss varies according to the type of forging or
smithy work and can only be dealt with properly by charging the gross
weight of metal issued to the work order concerned, and crediting the

amount realized from the total scrap from the smithy to 'shop oncost'. In
the case of those jobs in which these losses are particularly heavy, the cost
of scrap should be credited to the jobs. There are metal losses by scaling
and sometimes by ends left over on account of irregular lengths and sizes
of bars, & c, but these later can hardly be considered as scrap. The amount
realized from such metal should also be credited to shop oncost.
Wastage—The percentage of wastage should not be 'assumed' and the
instruction in regard to the ascertainment of wastage in foundries apply
with equal force to the Smithy and its connected shops.
Defective Products —Defective products are not likely to figure to any
extent in the Smith Shop Accounts and any correction found necessary
after checking over the job is usually better corrected under the original
order. When defects are due to defective material or other exceptional
cases, the matter should be brought to the notice of the Production
Engineer and his orders for the disposal of such defective products
obtained.
Carriage Component Shop
Carriage components are the items that are machined for the purpose of
carriage in the coach and drain wastes produced during the premise and
run life of the train. This part of the workshop generally deals with the
sheet metal operations in large with a pinch of welding in order to create

an assembly.
Various machineries used here are basically a plethora of dies and press.
Different type of presses present in the shop are:-
 Press dreck
 Vertical Shearing Machine
 Hand Sheet blanker
 Hand Sheet Press
 Guletting Shearing Machine
 Trimming Press
 Front Shearing Press

Various product outcomes of carriage component shop are:-
Angle Lug, U-plug for the Anchor-link bracket, Wheel tag, Bracket and
the clamps, Body side pillar for the ICF Coaches, Steel Mug Holder,
Stiffing Prop, Back rest Catch Bottom Cover Complete, Top Liner for
Lower Hytrel Washer, Side Panel with lug, Alarm Signal Box, Chute
complete for Washbasin, Suggestion Box for S.L.Rs, Feed box for the
dogs, Side Wearer Cap (I.C.F.), Suspension arrangement for Air reservoir,
Seat Support Bracket Double, Funnel for Drain Pipe, etc.

HEAT TREATMENT SHOP
Heat treatment is the process of heating and cooling of a material to
change its physical and mechanical properties without changing the
original shape and size. Heat treatment of steel is often associated with
increasing its strength, but can also be used to improve machinability,
formability, restoring ductility, etc. Basic heat treatment process for steels
are described in the following subsections.
DIFFERENT TYPES OF HEAT TREATMENT PROCESSES
 Hardening.
 Tempering.
 Austempring.
 Martempring.

 Annealing.
 Stress relieving.
 Spheroid zing.
 Normalizing
 Case hardening.
 Cyaniding.
 Flame hardening.
 Induction hardening.
 Nitriding.
Here the operations are majorly performed over the different type of
furnaces in different kind of flames. There is an open tank of water and
multiple other tanks of oil or other dissipiant used whenever rapid
quenching is required.
ANNEALING
Annealing is one of the most important heat treatment operation applied
to steel. It is the process of heating the steel in a furnace to a point not
exceeding 50° above its upper critical point and maintaining the steel at
that temperature for a considerable time (30-60 minutes) to convert the
whole steel to austenite. Steel is allowed to cool down slowly through a
medium of hot sand, hot ashes or hot lime dust. The rate of cooling is to
be maintained at 150-200ºC per hour.
HARDENING
In hardening process, the steel is first heated to a point exceeding 50ºC
above the upper critical point for hypo-eutectoid steels and 30-50ºCabove
for hyper-eutectoid steel. Then the steel is soaked at this temperature for
a considerable time to ensure that all the pearlite and cementite have
changed into austenite. After that the steel is cooled rapidly to keep the
austenite to remain as such at room temperature. This process consists of

two operations – heating and quenching. If these two operations are
properly carried out, then the required structure is obtained.
MARTEMPERING
Martensite is stable only up to 200ºC. If a piece of steel, which has been
hardened, is subsequently heated to a temperature above 200ºC, the
decomposition of martensite will start taking place. This decomposition
is in the order of troostite first and then sorbite. Martensite decomposes
into troostite, which is a finely dispersed mixture of cementite and ferrite,
in the temperature ranges of 200-300ºC. Tempering at temperature
between 500-600ºC will lead to the formation of the globular structure of
sorbite. The object of tempering is to remove excessive brittleness and
induce toughness.
Heating in the Bogie-Hearth Furnace and the quenching tank of
water and oils

SPRING SHOP
In this section the helical and leaf spring are prepared. The helical spring
is the most commonly and vastly used in the coaches as well as in the
engine. Every helical spring undergoes a specific set of testing before
application in the coaches. For this purpose there are certain machine for
testing, grading and repairing it. All materials to some degree show elastic
properties and will deform to some extent when they are subjected to
external loads. “When the load is removed, the material will return to its
original shape” without any deformation provided its elastic limit is not
exceeded. A material which shows these properties can be considered a
spring
TESTS PERFORMEDON HELICAL AND LAMINATED SPRINGS
 Visual and magnetic crack detection.
 Spring scraping machine.
 D’ buckling
Visual and magnetic crack detection. The visual test with the help of magnifying
lens and glass the spring the 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, corrosionand breakage.
CAUSE PERCENTAGE OF FAILURE
Free of height 8.93%
Load test 82.08%
Dent mark, corrosion& breakage 08.39%

SPRING SCRAGING
After the buckling test, the spring should be put onscraping 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 betest suchas, 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
compressionis 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
1. Over camber of the spring.
2. Short camber of the spring.
3. Leaf broken.
4. Gap between the leaves of the spring.
D’ BUCKLING
On this machine, buckling is performed on laminated spring. The leaves of the
springs are assembled and pressed. Now it is put on the buckling machine axial and
longitudinal forces are applied.

CLEANING AND SHORT PINNNING OPERATION ON SPRING
Short Pinning operation is performed in the Airless Centrifugal Shot
Blasting Machine following the given flow chart.
After this Operations, Testing of the spring is done. Majorly two operations are
required to be performed:-
a. Load Detection on Coventry Load Testing Machine
b. Crack detection by M.P.I. on Magna-flux Testing Machine.
First the crack detection is done, reason being the primary rejection is done on the
basis ofCrackand not the Load. TheCrack detection is donefollowing the following
algorithm:-

After this the load testing is done majorly in the Coventry Load Testing Machine
following the following flowchart:-

WHEEL AND AXLE 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 correctprofile with proper diameter.
The diameter of new wheel is-
Type Wheel dia. Distance b/w
journal center (mm)
Journal
size(mm)
Axel wheel seat
dia. (mm)
ICF 915 2159 120*113.5 172,0.25,0.35
BMEL 915 2210.2 120*179 171,0.45,0.63
Wheel can be used certain minimum diameter after which it is discarded. The
diameter of the wheel when it is condemned are-
S.N 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 consistof-
(1) Axle journal testing lathe.
(2) Hydraulic wheel press with facility of mounting.
(3) Axle turning lathe.
(4) Vertical turning lathe.
AXLE JOURNALTURNING LATHE

On this lathe, the diameter of the axel is brought to the correct diameter. The
cutting toolis used of carbontool.
HYDRAULIC WHEEL PRESS WITHA FACILITY OF MOUNTING
The wheel is pressed on the axle with the help of this machine. A calculated
amount of pressure is applied and the wheel is pressed.

AXLE TURNING MACHINE
External and internal diameter is corrected by this lathe, wheel is tightened on the
rotating clutch. The stationary is carbide toolcut the wheel to correctdiameter. This
section was completed in the Machine shop only using a C.N.C. In this shop surface
commissioning is done so as to remove the rust and wear due to atmosphere on the
surface ofthe wheel. This process notonlyenhances the surface finish but also gives
surface tolerance due to washing in after machining.
VERTICAL TURNING LATHE
On this machine the bore of the wheel is adjusted so as to press the axle inside the
bore on the Computer operated hydraulic press.

ROLLER BEARING SECTION IN THE WHEEL-AXLE SHOP
Roller Bearing Section in the NER deals with the processing and testing of the load
bearing slots and disks. Initially the cleaning process is done in the Bosch – Water
tank and Roller Bearing Cleaning Plant.
Bosch- Tank is basically the cleaning tank with a prepared solution. The roller
bearing is dipped into the solution in order to create a film of protective layer and
wash out the earthly gangue. Composition ofthre solution in the Boschtank is given
in the following table:-

Roller Bearing Section is the assembly of parts given in the following figure:-
The assembly is preheated on the induction heater to increase the boreand adhesion
in the assembly parts.
Then the heated assembly is tested using the Ultrasonic testing machine for different
Roller track crack, roller crack, cage crack, outer race crack and inner race crack.

Then this assembly is axially placed on the outer axle and wheel. Then this roller
bearing is pressed by the C.N.C. wheel press unit.
Final Completed assembly after the Wheel shop and Roller-
Bearing Shop

Bogie shop
Railway bogies are hardly noticed by the average passenger but they are
an essential part of the train, its drive system and its guidance mechanism.
A standard railway vehicle will have two bogies, generally located near
the vehicles ends. Each bogie is a 4-wheeled or 6-wheeled truck that
provides the support for the vehicle body and which is used to provide its
traction and braking. Each carriage (called a car in North America and
some other English speaking countries and still so called in the electric
traction business) has two bogies. The bogies support the mass of the
vehicle, use the wheels to guide italong the track and provide some degree
of cushioning against the shocks transmitted from the track during motion.
See also Vehicle Suspension Systems.
Bogies may be powered, either by electric motors of some type of
mechanical drive connected to a motor of diesel engine. They may also
just provide the carrying function - so-called trailer bogies. Both motor
and trailer bogies are normally braked, under the control of the train
braking system.
A pair of train wheels is rigidly fixed to an axle to form a wheelset. The
wheels are pressed on to the axle so that they both rotate together. As
we’ve seen above, normally two wheelsets are mounted in a bogie, so the
bogie is simply a 4-wheeled truck – the Americans call it a truck –
mounted under a railway carriage in order to support and guide the
carriage along the track.
In NER Gorakhpur Workshop the wear out bogie is brought. Then
initially it is De-Wheeled and then the bogie is individually handled. First
the bogie parts are physically analysed for the anchor links and guide
assembly. Then the Bolster assembly is followed in which the spring and
wheels are attached to the assembly. Then the bogie is painted using the
black iron emulsion coating and passed upon in the brake shop and other
shop for final installation and checking.

Brake shop
BRAKING SYSTEM
Working-By means of frictional force between wheel and brake pad.
Mainly two types of braking system is used-
1. Air-Braking system.
2. Vacuum-brake system.
3. Electronically control Pneumatic Brakes
AIR BRAKING SYSTEM
This is new method of braking system, which is more efficient than the vacuum
brakes. It is used at first in Rajdhani and Shatabdi coaches. Progress conversion of
vacuum brakes in air-brake has being undertaken.
ELECTRONICALLY CONTROLLED PNUMETIC BRAKES
Electronically controlled pneumatic brakes (ECP) are a development ofthe late 20th
Century to deal with very long and heavy freight trains, and are a development of
the EP brake with even higher level of control. In addition, information about the
operation of the brakes on each wagon is returned to the driver's control panel.

This prevents wagons at the rear "shoving" wagons at the front, and results in
reduced stopping distance and less equipment wear.
MAIN PARTS OF AIR BRAKE SYSTEM
1. Brake cylinder.
2. Brake pipe.
3. Feed pipe.
4. Distributer pipe.
5. Angle lock.
6. House pipe.
7. Auxiliary reservoir.
8. Guards van valve & pressuregauge.
9. Isolating cock.
DESCRIPTION OF SOME IMPORTANT PARTS OF AIR
BRAKING SYSTEM
BRAKE CYLINDER
There are two 355 mm brake cylinder under frame, which is fed by common
distributor valve. It has the piston-rod arrangement, which works under pressure.
Brake cylinder is connected to distributor valve on one side and by pivot to the
block cylinder.

MOUNTING OF AIR BRAKES
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.
BRAKE DISC IN COACHES
HOUSE COUPLING
Both the brake-pipe and feed pipe are fitted to the angle cockoutlet for the passage
of compressed air from one coachto another mean of braided rubber and metal
coupling.
GUARD VAN VALVE AND 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 cockis kept parallel to the pipe to indicate that it is in
open conditions.

Shell shop
Shell shop is divided into two parts-
1. Fitting Shop
2. Welding Shop
MAIN PARTS OF SHELL
Various parts of shell are as follows-
1. Under Frame
 Sole Bar
 Head StockAssembly
 Body Bloster Assembly
 Through Floor
 Crops Bearer
 Tubular Structure
2. Side Bar
3. Roof
4. End bar
5. Center Pivot (Guide of turning of train)
FITTING SHOP
Fitting work is a very important work in engineering. In fitting shop unwanted
material is removed with the help of hand tools. It is done for mating, repair and
manufacturing purposes. The person working in the fitting shop is called a fitter. A
fitter should have the complete knowledge of the tools used in the shop. Commonly
used tools are hacksaw, files, chisels etc.
WELDING SHOP
Welding is a fabrication or sculptural process that joins materials, usually metals or
thermoplastics, by causing fusion, which is distinct from lower temperature metal-
joining techniques such as brazing and soldering, which do not melt the base metal.
Some of the best known welding methods are

1. Shielded metal arc welding (SMAW)
2. Gas tungsten arc welding (GTAW)
3. Gas metal arc welding (GMAW)
4. Flux-cored arc welding (FCAW)
5. Submerged arc welding (SAW)
6. Electro slag welding (ESW)
TYPES OF WELDING USED IN SHOP
1. CO2 arc welding
2. Manual metal arc welding.
3. Bharat cutting gas(B.C.G.)
4. Liquefied Petroleum Gas
5. Oxy-acetylene gas welding
GAS WELDING
The most common gas welding process is oxy-fuel welding, also known as oxy-
acetylene welding. It is one of the oldest and most versatile welding processes, but
in recent years it has becomeless popular in industrial applications. It is still widely
used for welding pipes and tubes, as well as repair work.
The equipment is relatively inexpensive and simple, generally employing the
combustionof acetylene in oxygen to produceawelding flame temperature of about
3100 °C. The flame, since it is less concentrated than an electric arc, causes slower
weld cooling, which can lead to greater residual stresses and weld distortion, though
it eases the welding of high alloy steels. A similar process, generally called oxyfuel
cutting, is used to cut metals.

Given above are the used inflammable shop used in the shop. This
cylinder is then asssed with a welding torch and then welding is done in
prescence of flame and flux. The whole assembly is then assembled
holistically with sufficient time and precision.

FURNISHING SHOP
PAINT SHOP
The Work of this shop is to paint the coaches and bogie. In this shop there are
many sections and they are following –
1. CoachPainting
2. Letter Section
3. Trimming Section
4. CorrosionSection
5. Polish Section
PURPOSE OF PAINTING
1. For protection against corrosion
2. For Decoration
3. For covering
MATERIAL USED IN PAINTING
1. Paint Materials
2. Enamel Materials
3. Varnish Materials
4. Laquer Materials
PAINT MATERIAL
1. Base
2. Binder
3. Thinner
4. Drier
5. Pigment
6. Inert or Filler Material
THE MAIN PROCESS INVOLVE IN PAINTING
Firstly, Putin is prepared and it gets filled at the places where holes and cracks has
been found. Secondly, the primer is put on the bodyand then finally painting is done
in order to give the body desire shape.

The overhauling of the coaches has been in given time interval it improves the
quality of coaches and it also prevents the coaches from break down. The
maintenance of coaches is according to time being is done as following-
1. MAIL EXPRESS- 12 MONTHS.
2. PASSENGER- 18 MONTHS.
3. NEWLY COACHES- 24 MONTHS.
SEAT SHOP
There are variety ofseats depending uponthe type offacility in the coachand general
distinctions like the type of the coach – 1AC, 2AC, 3AC, SL or GEN coaches. They
all have different type of seats decided on the level of the comfort the Indian
Railways decide to provide to their customers which primarily comes out after
interviewing different sect of people ranging from common men to VIPs.
At NER Gorakhpur Railway Workshop primarily two types of seats are framed and
assembled to the seat slot of the shell of the coach. These are for SL- seating and
sleeping section, ACs sleeper seats and General Coach all seats.
The productiondone in this shop follows the scheduling requirements on a monthly
basis and depending on which daily prouction is being carried out. The raw material

for this shop are hig grade cushion materials, base and Raxine covers.
AC- SHOP
Air conditioning basically are mounted upon the roof of the coach following
conventional type packing RMPU technique. The coach is equipped with two
compactair conditioning units installed in the roofarea at the coachtails above false
ceiling. These units are supplied by three phase mains.
Control and regulation are carried out by a common controller, mounted in switch
cabinet S1 and fed from battery net. The operating and display elements of the air
condition control are equally contained in the switch cabinet S1.
SALIENT FEATURES OF LHB TYPE RMPU AC COACHES
 Provision of IGBT based battery charger.
 Microprocessor based AC package with low noise level.
 Integrated modular single switch board with controls of AC & lighting etc.
 Lightweight epoxy moulded transformer.
 On line insulation monitoring.
 Modular and elegant interior light fittings and reading lights.
 Provision of radox type FRLS cables.
 Uniformity of illumination as per UIC.
 Microprocessor based pump line.
 Antiskid protection

 Modular toilets with electro pneumatically controlled toilet fittings.
Controlled discharge type toilet with microprocessor control.
 Moulded GRP paneling and antiskid PVC flooring.
 Microprocessor controlled disc break system with wheel slip control device.
 Centre buffer coupler with anti-climbing features.
Main Electrical Equipment
 Microprocessors controlled package unit.
 Switch board cabinet S1
 60 kVA transformer
 Battery charger
 Disconnecting and earthing device
 Safety devices
 110V, 70AH VRLA battery
 Fuse box
 Pump box
 NTC type temp sensor
Compressor kept in batch for Leak-Back
testing

At NER Gorakhpur Railway Workshop the first process is basically of testing the
faults in the brought part of the LHB RMPU based AC body, Basic installation of
the Compressor is done after performing following operations:-
Volumetric Efficiency Test done by following the given table instructions:-
LeakBack Test done by following the given table instructions:-
Temperature Rising Test done by following the given table instructions:-

SubmergeTest done by following the given table instructions:-
Then the compressoris installed to the assembly of the AC bodyand this assembly
is the placed on the roofusing overhead cranes and various attaching arrangements.
The end connections of the batteries and the electric supply is done in the
powerhouse where entry of the trainees is banned without proper approval and
guidance of the officials.

WATER-TANK SHOP
Various Water tanks of different capacities and material are fabricated,
assembled or prepared here. The prepared water tank is then tested in
order to prevent water wastage during travel usage. Water harvesting is
the major priorities and Indian railways claim to save around 400 gallons
of water every day through their techniques.

MATERIAL HANDLING SYSTEM
Material Handling is the field concerned with solving the pragmatic problems
involving the movement, storage in a manufacturing plant orwarehouse, controland
protection of materials, goods and products throughout the processes of cleaning,
preparation, manufacturing, distribution, consumption and disposal of all related
materials, goods and their packaging Material-handling equipment is equipment that
relate to the movement, storage, control and protection of materials, goods and
products throughout the process of manufacturing, distribution, consumption and
disposal. Material handling equipment is the mechanical equipment involved in the
complete system..
Different Material handling mechanisms adopted by the Workshop are :-
 Over Head Crane
 Conveyer Belt
 Small Trucks
OVERHEAD CRANES
An overhead crane, commonly called a bridge crane, is a type of crane found in
industrial environments. An overhead crane consists of parallel runways with a
traveling bridge spanning the gap. Overhead cranes are commonly used in the
refinement of steel and other metals such as copperand aluminium. Overhead Crane
in Workshop were used to lift and displace parts like wheel- axle assembly, bogies,
shell, AC chasis and overhead tanks.

CONVEYER BELT
A conveyor belt is the carrying medium of a belt conveyor system (often shortened
to belt conveyor. In Workshop Conveyer Belt was used at different levels during
testing like magnetic testing, moving assemblies, stocks, seats, etc.
SMALL INDUSTRIAL TRUCKS
Industrial trucks were used in workshop for:-
 Used to move materials over variable (horizontal) paths with no restrictions
on the area covered (i.e., unrestricted area) as lifting capabilities.
 Used when there is insufficient (or intermittent) flow volume suchthat the use
of a conveyor cannot be justified.
 Provide more flexibility in movement than conveyors and cranes.
 Not licensed to travel on public roads—"commercial trucks" are licensed to
travel on public roads.

OBSERVATIONS AND REPORT
1. In the Machine Shop all the operations are performed ranging from facing,
centring, turning, boring, drilling, thread cutting and many more. All these
operations are performed by a skilled labour set on the most basic Centre
Lathe to pre-programmed CNCs. The iron extruded bars are supplied by
TATA STEEL plant from Jamshedpur and many other location, Wheel and
axle blocks by SAIL, Durgapur Plant. The production outcome of machine
shop are –
A. Wheel and Axles made on CNCs.
B. Fasteners like Screw, Nut, bolts made on Lathe Machines.
C. Drawbars and Pull-bars made on Milling Machines
D. Collars, Treads and Hubs made on Shaper and Slotters.
E. Knuckle Pivot Pin
F. Rivet Head
Description of Wheel and Axle products Used:-

Different supplies range from cylindrical iron bars of different diameters,
hexa-section bars of different dimensions, high strength iron graded wheel
cylinder of specified diameter and bore, Heat treated axle rods.
2. In Smithy Shop themain operations undertaken were to rivet the shockerglass
with the circular steel plate using a rivet head. The rivet head was preheated
on an Open-Furnace fuelled by coal. It was then placed manually along the
bore of steel plate and shocker glass then hammered for penetration and then
allowed to cool down. Then the surface was properly smeared using
horizontal hand grinders. Other operations performed were Laser cutting, Gas
cutting of steel sheets to circular plate.
In carriage component shop major operations performed where SHEET
METAL ones. They were performed on white iron sheet or steel sheets of
different thickness majorly greater than 6mm. The operation performed onthe
press where blanking, nibbling, Bending, Shearing, Trimming, Embossing,
etc. The main production outcomeof this shop are boxes, welded drain pipes,
etc.
3. In Heat Treatment Shop all the operations were majorly performed on the
furnaces like New Bogie Hearth Furnace, Fixed Hearth Furnace, OpenHearth

Furnace, Electric Furnace, Double Chamber Furnace majorly used for basic
Heat Treatment Operations like Stress Relieve, Cleaning, Annealing,
Hardening, Case-Hardening, Hardening, Quenching, Normalising,
Carburising, Nitriding, etc. The material was first heated to a predetermined
temperature by placing it in the furnace. Then, the material was checked for
even heating and quenched in the required dissipiant medium depending upon
the process ofheat treatment being performed upon. Various parts being heat
treated are; Lower Spring Seat protection tube, Buffer plunger I.C.F., Hanger
Axle Box Housing, All forging equipment.
This shop required Skilled Labour and had a better layout for waste-disposal
techniques, etc.
4. In spring shop the spring was imported from the Railway Spring Factory at
Central-North zone of railways basically from Mitholi, Gwallior. This
imported springs are checked for their properties like crack on surface, sub-
surface or lattice. Then passed from here they are verified for load bearing
capacity. Shot-Pinning of the spring is done in order to relieve them from the
residual stresses generated during their manufacturing. Then the passed
springs are bituminous coated to install in the bogies.
5. In wheel axle shop initially the bore and steps of both the wheel and axle
previously girded and machined in earlier shops is met to the requirement of
the assembly. Then the axle is pressed into the wheel using the computer
operated hydraulic press. This completes the assembly and then anchor links
are placed in the slots of wheel and the assembly is lifted up through overhead
cranes. As informed this process onceturned out fatal as the anchor link broke
during the flight. Thus to prevent this situation the anchor links are checked
for crack and load every now and then. Then the roller bearings are placed
axially into the axle from outer side in the roller bearing assembly section.
Details of the process are mentioned earlier in the Wheel axle section.
6. In Bogie shop the basic framework is of repair and follow the Bolster
assembly strictly. Also all the component except the electric one are installed
in this shop holistically. The Bogie brought here is initially physically
analysed for all kind of the defects and severe damages during the run time of
the bogie. Each part is bolted and analysed following different type of testing
procedure in the screw coupling zone. Various test like load test, shear test,
tensile test, crack test, Zyglo test, etc. are done here before and after
installation. The readied assembly is the marched onto the powerhouse for
battery installation and other kind on tests.

7. In Brake shop basically two brakes are first assembled part by part and then
installed to the bogie – wheel axle assembly. These two types of brakes are
A.B.S and E.C.P brakes. The assembly is done byvery skilled labour as minor
faults would lead to catastrophic failure of the brakes and which may lead to
rail accidents.
8. In Shell shop the outer boundaryof the coachis repaired in this workshop. As
informed to us the major coachframework is done in the Southern and North-
west railway due to sufficient availability of resources and cheap manual
labour. The basic operations done here are welding and fitting done by
medium skilled workers thus distributing the wages unevenly and in a way
that depends upon the labour skill quality.
9. Furnishing is high costintensive job as everything is purchased from the third
party firms like H.E. Ltd., Crompton. The testing and installation is donewith
conventional techniques. In AC shop the engineering section basically dealt
with the quality check of the supply of the compressor for various standards
pre-fixed by the Indian railway R&D department. In the paint shop various
kinds of paints like enamel coat, bituminous coal, mineral paints are mixed
with the dryer and the other chemicals. Then the coach is painted by the
painters. Also flooring of the coach is done in this section- It’s a three layer
coat of base, cushion and epoxy sheets. In seat shop the basic stitching of the
seat covers require labour and assembly is also done by them for bot AC and
SLEEPER coaches. In the water tank shop the emphasis is given to make the
water compartment sealed and leak-proof.
Outlines of report:-
1. Skilled labour with good work involvement, determination to completion of
job and experience.
2. Some of the labourers lacked technical knowledge of machinery they were
handling.
3. NERs Women-Empowerment approach by giving equal chance of
involvement to women in workforce.
4. Lot of Waste generation. No emphasis on recycling at ground level.
5. Fair amount of cleanliness due to boom of Swach Bharat Abhiyaan.
6. Job Scheduling type was of Preventative Machine Scheduling. It followed the
basic concept of Batch Production on regular basis to prevent the Mismatch
of excessive demand and meet the required demand anytime.

REFERENCES
1. Codes Manual of Indian Railways-
http://www.indianrailways.gov.in/railwayboard/uploads/codesmanual/Mech
Dept/Mechanical_index.html
2. Report of the Court of Inquiry into the Circumstances Attending the Double
Collision on the Great Northern Railway which occurred at Abbotts Ripton
on the 21st January 1876, HMSO, 1876
3. Merriam-Webster, Merriam-Webster's Collegiate Dictionary, Merriam-
Webster.
4. Houghton Mifflin Harcourt, American Heritage Dictionary of the English
Language (5th ed.), Houghton Mifflin Harcourt.
5. Oxford Dictionaries Online, Oxford Dictionaries Online, Oxford University
Press.

6. Open Sources like
http://www.wikipedia.org
http://www.slideshare.org
http://www.google.com
http://www.scribdd.org
7. Data of Indian Railways System given by Er. R.M. Srinivasan, Head South-
East Zone Indian Railways.

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