about indian railway, history of indian railway, mechanical workshop, painting shop, welding shop, heat treatment shop, spring section, machine shop, inspection shop etc.
2. ABOUT INDIAN RAILWAY
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.
As of December 2012, it transported over 25 million passengers daily (over 9 billion on an
annual basis).
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.
Indian Railways is the world's ninth largest commercial or utility employer, by number of
employees, with over 1.4 million employees.
Controlling headquarters Zonal management
Central railway CR Mumbai
East central Railway ECR Hajipur
Eastern Railway ER Kolkata
East Ccoast Railway ECoR Bhubaneswar
3. HISTORY OF INDIAN RAILWAY
First Indian Railway line was opened on 16th April 1853.
The first train consisting of one steam engine and four coaches , traversed a stretch of 21-
miles between Mumbai(Bombay) and Thane.
The British government encouraged the setting up of railways by private investors under a
scheme that would guarantee an annual return of 5% during the initial years of operation.
Once completed, the company would be passed under government ownership, but would be
operated by the company that built them.
4.
5. GORAKHPUR RAILWAY STATION
MECHANICAL WORKSHOP
Gorakhpur mechanical workshop is established in 1903 for repair and over hauling purpose
of steam locomotives , coaches and wagons.
At present it is used to periodic over hauling and maintenance purpose of AC and NON-AC
coaches.
The workshop having capacity to overhauled 180 coaches per month.
Gorakhpur railway station now become world largest platform.
TOTAL AREA COVERED - 29.8 HECTARE.
COVERED AREA– 12.6 HECTARE.
NUMBER OF OFFICERS- 19
NUMBER OF SUPERVISORS- 378
TOWNSHIP AREA- GORAKHPUR
POWER CONSUMPTION- 208662 KWH
6. LIST OF SHOPS IN GORAKHPUR
RAILWAY STATION
INSPECTION SHOP
MACHINE SHOP
PAINTING SHOP
WHEEL AND SHAFT SHOP
SPRING SECTION
HEAT TREATMENT SHOP
JIG AND FIXTURE
WELDING SHOP
7. INSPECTION SHOP
This shop is used for inspection purposes.
A list of experts came in the shop and listed the errors and problem occurred in the coaches.
Then they make a major or minor list for the coach.
If the problem is small it is solve immediately in that shop and in not it is send for the further
shops.
8. MACHINE SHOP
In this section all kinds of machining is done to obtain the correct size and shape of the job.
MACHINE SHOP IS DIVIDED INTO TWO CATEGORY
1. Automatic machine (N.C.boring, CNC lathe, heavy drilling machine etc)
2. Manual machine (drilling machine, shaper, slotter, planner , lathe etc)
The different type of machining is done on this shop.
The machine shop is divided into different divisions:
1. Capstan and turret lathe section
2. Milling section
3. Drilling section
4. Heavy machine section
9. HYDRAULIC WHEEL PRESS MACHINE
It is used to mounting the shaft and wheel by
the help of hydraulic pressure (72-108 ton).
The machine has the capacity of 500 ton.
Allowance is 0.2- 0.5 mm between shaft
diameter and wheel diameter.
Lubricant use for this operation is boil lean
seed oil + white lean powder
lubricant increases the strength and contact
between wheel and shaft .
To remove the wheel from shaft double
pressure is required.
10. VERTICAL TURRET LATHE MACHINE
It is used to make the bore in Rail Wheel.
The bore diameter of rail wheel 168.778- 177.8 mm.
Maximum depth of cut of turret lathe is 6 mm.
Total time for bore is 45-50 minute.
The disc is made up of gray cast iron.
11. PAINTING SHOP
In this shop painting has been done of
different parts of coaches and bogie.
Painting is done by either manually or by
spray machines as per requirement and
depending upon work load .
The spray machines consume more paint
and wastage of paint is more.
Manual painting is slow but no wastage of
paint .
12. WHEELAND SHAFT SHOP
In this shop repair of wheel and shaft(axel) is undertaken.
The wheel is first tested on wheel testing machine.
And after that further treatment is done on the basis of result of testing.
The shop consist of machine like-Axel journal testing machine, Hydraulic wheel press
machine , Axel turning lathe, vertical turning lathe.
13. SPRING SECTION
In this section coil and leaf spring are
made.
The testing of leaf spring is also done
in this shop by
(1)Visual and magnetic crack
detection.
(2)Spring scraping machine.
(3) D’ buckling machine.
Various other machines in this shop-
Quenching tank, Tempering furnace,
Rolling machine, Cambering machine,
Hardness testing machine.
14. HEAT TREATMENT SHOP
Heat treatment is the process of heating and
cooling of material to change its physical and
mechanical properties without changing the
original shape and size.
In this shop machine parts are heated for long
time below its melting point and after that some
parts are cooled in water and some parts are
cooled in air or oil as per physical and mechanical
properties is required
In workshop mainly the heat treatment is for
suspension hanger , different processes is used;
CARBURIZING:
It also referred to as Case Hardening, is a heat
treatment process that produces a surface which is
resistant to wear , while maintaining toughness
and strength of core.
15. It is applied after the machining process.
For suspension hanger in Indian railway carburizing take place for 20-22 hour
Pre heat 5.5 hour temp 950 degree
Hold 15.5 hour temp 950 degree
REFINING:
It remove impurities or unwanted element from a substance .
It is nearly 2.5 hour process and temp required is 860 degree Celsius.
HARDENING:
This treatment will result in an improvement of the mechanical properties as well as an
increase in the level of hardness , producing a tougher , more durable item.
Alloys are heated above the critical transformation temp for the material then cooled rapidly to
get stronger structure .
18. WELDING SHOP
Type of welding operations used in shop
1. Welding
2. Soldering and
3. Adhesive bonding
4. Brazing
19. BREAKING SYSTEM
The breaks are used on the coaches of railway train to enable deceleration, control acceleration
or keep them standing when break is fully applied.
While the basic principal is similar to road vehicle.
There are two types of breaking system is used:
1. VACCUM BRAKE SYSTEM
2. AIR-BRAKE SYSTEM
DISK BREAKING SYSTEM
20. AIR -BRAKE SYSTEM:
This is new method of breaking system, which is more efficient than the vacuum brakes
It is used first in Rajdhani and Satabadi coaches.
