IN-PLANT TRAINING REVIEW

INTEGRAL COACH FACTORY INDIAN RAILWAYS

Sudarshan. MRA1411002040113

Mechanical – ‘B’IIIrd Year

Introduction• INTEGRAL COACH

FACTORY IS THE ONLY MANUFACTURER OF RAIL COACHES LOCATED IN CHENNAI. IT IS OWNED AND OPERATED BY THE INDIAN RAILWAYS.

• ICF is the first of its kind to be established after Independence for the manufacture of light weight, all steel and all welded Integral railway passenger coaches.

• The plant employs about 13,000 people and manufactures about 1500 coaches per year.

• A total of 50,000 coaches had been produced till 18 Aug 2015 by ICF since its inception

A Brief History Of IcfTHE INTEGRAL COACH FACTORY WAS SET

UP IN 1951 WITH THE HELP OF M/S SWISS CAR AND ELEVATOR MANUFACTURING CORPORATION LTD., SCHLIEREN-ZURICH (SWITZERLAND).

IT WAS INAUGURATED BY THE THEN PRIME MINISTER OF INDIA PANDIT JAWAHARLAL NEHRU ON 02 OCT 1955.

PRODUCTION BEGAN IN A MODEST MANNER IN 1955 WITH THE MANUFACTURE OF SEVEN THIRD CLASS COACH SHELLS

INTEGRAL COACH FACTORY

Shell Division Furnishing Division

SHOP 10 & 11 SHEET METAL

PROCESS

SHOP 22SIDE AND END

WALL ASSEMBLY

SHOP 21 ROOF ASSEMBLY

SHOP 30FURNINSHING

SHOP 37 AIR BRAKE ASSEMBLY

SHOP 54PAINTING

SHOP 10: SHEET METAL PROCESSING• STAGE 1: STRAIGHTENING BY

ROLLERS• STAGE2: RELAXATION• STAGE3: CUTTING OF SHEETS

MATERIALS USED• COR-TEN Steel

6mm• Mild Steel 6mm• Stainless Steel

4mm

SHOP 10: SHEET METAL PROCESSING

• CUT TO LENGTH MACHINE• ECCENTRIC PRESS• PROFILE BENDING• SEAM WELDING• BLANKING USING HYDRAULIC PRESS OF

TONNAGE 300-1000 TONS.

• LASER CUTTING CNC USING N2,H2, CO2

SHOP 11: SIDE WALL ASSEMBLY • THE SIDE WALLS OF THE

COACHES ARE BEING ASSEMBLED HERE.

• THE SHEET WHICH ARE CUT IN SHAPE AND BENDED IN REQUIRED PROFILE FROM SHOP 10 IS WELDED TOGETHER HERE.

• SPOT WELDING AND SURFACE WELDING ARE USED.

• THE WALL FIXTURES ARE MOVED BY OVERHEAD HEAVY TONNAGE CRANES.

• IT TAKES ABOUT A WEEK TO PRODUCE APPROX. 4-5 COACHES.

SHOP 21 AND 22: MAIN ASSEMBLY

SHOP 21 AND 22: MAIN ASSEMBLY• Shop 21 – Roof Assembly• Roof is assembled by placing

the sheet on special fixtures called Roof Jigs

• Electric Arc welding is mainly used.

• Minor joints are welded by Gas Welding.

• Shop 22 – Body Assembly• The body of four different

coaches are made here.• They are General Coach,

Second Day coach, Second Class Night Coach and Second Class Loading Unloading

METRO BOGIES SIDE FRAME

SHOP 30:FURNISHING

• 1. PREPARATORY – BODY IS LINED WITH FOAM AND INSULATION

• 2. FLOORING – PLYWOOD FLOORING IS DONE. MICA SHEETS

• 3. WIRING – INTERNAL WIRING AND OTHER ELECTRICAL FIXTURES

• 4. PVC PASTING • 5. PANELING – I

SHOP 30:FURNISHING

• 6. PANELING –II• 7. MOLDING• 8. FITTING – THE

FRAMES FOR SEATS OR BERTHS ARE FIXED

• 9. SEATS AND WORKS• 10. PIT LINE

INSPECTION – MANUAL INSPECTION IS DONE

SHOP 37 - BRAKING SYSTEM

• Air brakes system is generally used.

• Vacuum Brakes are used for minor braking purpose.

• Air brakes is classified into three parts 1. Auto Brake

2. EP Brake 3. Emergency Brake

SHOP 37 - BRAKING SYSTEM

• Electro Pneumatic Unit is used to control the system

• In this the brake assembly is made as designed.

• Leakage check is done using soap water.• The limit for verification is a 0.2kg pressure drop

in 15 minutes.

SHOP 54 : PAINTING• DEWHEELING OF BOGIES • FIXING OF DUMMY BOGIE• MASKING

• SHOT BLASTING – SHOTS

OF 2 – 3 MM DIAMETER• DEMASKING• EPOXY PRIMER – A.K.A

METAL PRIMER (2 COATS)• ENAMEL • OVEN

SHOP 54 : PAINTING• POLYESTER PATTY – TO COVER

DENTS• DUST CLEANING – AIR HOSE• SURFACER OR BASE PAINTING –

TO COVER PINHOLE GAPS• SURFACER FLATTENING – DONE

USING EMERY PAPER MANUALLY• WINDOW AREA SATIN GLUE

ENAMEL• AC BLUE ENAMEL• WHEELING • DISPATCH

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