1. INDUSTRIAL TRAINING REPORT SUBMITTED BY :- RAMESH KUMAR SHARMA BRANCH M.E SECTION B I.T.S ENGINEERING COLLEGE , GR.NOIDA

2. CONTENTS . HISTORY . INTRODUCTION OF EMU CAR SHED . TYPES OF TRAINS IN EMU CAR SHED . NO. OF SECTIONS . MECHENICAL WORKSHOP . COMPONENT MATERIALS . BOGIE . METALLURGICAL LAB . MEASURING & INSPECTION . TRACTION MOTOR . TURBO SUPERCHARGER . COMPRESSOR . PIT WHEEL LATHE . PENTOGRAPH

3. INDIAN RAILWAY HISTORY Indian Railways is the state-owned railway company of India. It comes under the Ministry of Railways. Indian Railways has one of the largest rail networks in the world, transporting over 18 million passengers and more than 2 million tonnes of freight daily. Its revenue is Rs.107.66 billion. It is the world's largest commercial employer, with more than 1.4 million employees.

4. . It operates rail transport on 6,909 stations over a total route length of more than 63,327 kilometers(39,350 miles).The fleet of Indian railway includes over 200,000 (freight) wagons, 50,000 coaches and 8,000 locomotives. It also owns locomotive and coach production facilities. It was founded in 1853 under the East India Company. . Indian Railways is administered by the Railway Board. Indian Railways is divided into 16 zones. Each zone railway is made up of a certain number of divisions. There are a total of sixty-seven divisions. It also operates the Kolkata metro. There are six manufacturing plants of the Indian Railways. The total length of track used by Indian Railways is about 108,805 km (67,608 mi) while the total route length of the network is 63,465 km (39,435 mi).

5. The broad gauge (1670 mm) The meter gauge (1000 mm) Narrow gauge (762 mm) Narrow gauge (610 mm). Indian Railways operates about 9,000 passenger trains and transports 18 million passengers daily .Indian Railways makes 70% of its revenues and most of its profits from the freight sector, and uses these profits to cross-subsidies the loss-making passenger sector. The Rajdhani Express and Shatabdi Express are the fastest trains of India

6. CLASSIFICATION . Standard Gauge designations and dimensions:- W = Broad gauge (1.67 m) Y = Medium gauge ( 1 m) Z = Narrow gauge ( 0.762 m) N = Narrow gauge ( 0.610m) . Type of Traction designations:- D = Diesel-electric traction C = DC traction A = AC traction CA=Dual power AC/DC traction . The type of load or Service designations:- M= Mixed service P = Passenger G= Goods S = Shunting

7. . Horse power designations from June 2002 (except WDP-1 & WDM-2 LOCOS) 3 For 3000 horsepower 4 For 4000 horsepower 5 For 5000 horsepower A For extra 100 horsepower B For extra 200 horsepower and so on. Hence WDM-3A indicates a broad gauge loco with diesel-electric traction. It is for mixed services and has 3100 horsepower.|~|

8. INTRODUCTION EMU CAR shed is an industrial-technical setup, where repair and maintenance works of EMU & DEMU is carried out, so as to keep the loco working properly. It contributes to increase the operational life of EMU & DEMU and tries to minimize the line failures.

9. . The shed consists of the infrastructure to berth, dismantle, repair and test the loco and subsystems. The shed working is heavily based on the manual methods of doing the maintenance job and very less automation processes are used in sheds, especially in India. The EMU CAR shed usually has:- Berths and platforms for loco maintenance. Pits for under frame maintenance Heavy lift cranes and lifting jacks Fuel storage and lube oil storage, water treatment plant and testing labs etc. Sub-assembly overhauling and repairing sections Machine shop and welding facilities.

10. TYPES OF TRAINS IN EMU CAR SHED There are three trains are inspection and maintenance in EMU CAR shed. These are as follow :- 1. EMU 2. MEMU 3. DMU

11. EMU & MEMU

12. 1. EMU In EMUs one power car (motor coach) is required for three coaches so for an EMU has 12 coaches in length will have 4 power cars & mainly runs in the suburban sections of major cities. It considered as normal local trains such as life line locals of MUMBAI, HYDERABAD, CHENNI etc 2. MEMUs In MEMUs one power car in needed for 4 coaches so MEMU are normally has 16-20 coaches long. It runs for long distance more than the suburban sections . It runs on the same line on which normal Local/Exp/Mail/SF trains runs. MEMU Vadodara Ahmadabad MEMU MEMU were modified EMUs introduced in 1993-94 3. DEMUs In DEMUs , generally runs on diesel which tank capacity about >4000lts. It named as overhead electric inspection car used in repair & maintenance of overhead cables which fitted above the roof of trains carries 25kv A.C supply.

13. SPECIFICATIONs:- Compressor - 8kg/cm2 Engine type V type engine, clockwise rotation Lubricant used servo plex TM-3 , servo press 150 Fire order - 1L-6R-2L-5R-4L-3R-6L-1R-5L-2R-3L-4R

14. NO. OF SECTIONS 1 . MECHANICAL WORKSHOP 2 . ELECTRICAL WORKSHOP 3 . PAINTING WORKSHOP

15. MECHANICAL WORKSHOP 1. MEASUREMENT & INSPECTION SHOP 2. CARPENTARY SHOP 3. PENTOGRAPH SHOP 4. MACHINE SHOP 5. J.S.L TYPE BRAKE CYLINDER SHOP 6. POH SHOP 7. TRANSMISSION SHOP 8. COMPRESSOR SHOP

16. COMPONENT MATERIALS AXLE alloys 0.5 0.6 % C 0.8 1.0 % Mn 0.35 % Cr 0.7 % Mo BRAKE BLOCK Ferobestos It has crushing strength about 1.3 tones Density (1.95- 2.05 ) gm/m3

17. BOGIE

18. BOGIEs A BOGIE is a wheeled wagon or trolley. In mechanics terms, a bogie is a frame work which carrying wheels attached to coaches. It is subassembly of 2 axle, 4 wheel, 4 jsl type brake cylinder , 2 side bearer, 4 bearing(double roller bearing), helical spring etc

19. METALLURGICAL LAB Metallurgical lab. concern with the study of material composition and its properties. Specimens are checked for its desired composition. In this section various tests are conducted like hardness test, composition test e.g. determination of percentage of carbon, swelling test etc.

20. Function of some of the metal is tabulated in table below :- S.No. Compound Function 1. Phosphorous - Increase the fluidity property 2. Graphite - Increase machinability 3. Cementide - Increase hardness 4. Chromium - Used for corrosion prevention 5. Nickel - Used for heat resistance 6. Nitride rubber - Oil resistance in touch of O ring 7. Neoprene - Air resistance & oil resistance in fast coupling in rubber block 8. Silicon - Heat resistance and wear resistance (upto 600 C ) use at top and bottom pore of liner.

21. Swelling test Swelling test is performed for rubber in this test percentage increase in weight of the rubber after immersing in solution is measured and increase in weight should not be more than 20%. Two type of swelling test viz low swelling and high swelling are performed in the lab. Three type of oil solution are used for this purpose listed below:- ASTM 1 ASTM 2 ASTM 3 Procedure 1. Select specimen for swelling test Note the weight of the specimen Put in the vessel containing ASTM 1 or ASTM 3 Put the oven at 100 C Put the vessel in the oven for 72 hrs. After 72 hrs. Weigh the specimen.

22. Rubber Broadly there are two types of rubber: 1). Natural rubber- this has very limited applications. It is used in windows and has a life of 1 year. 2). Synthetic rubber- this is further subdivided into five types. VUNA-N (2 year life) Polychloroprene or Neoprene (2 year life) SBR (3 year life) Betel (3 year life) Silicone (3 year life).

23. ULTRASONIC TESTING In ultrasonic testing, very short ultrasonic pulse-waves with center frequencies ranging from 0.1-15 MHz and occasionally up to 50 MHz are launched into materials to detect internal flaws or to characterize materials. Ultrasonic testing is often performed on steel and other metals and alloys, though it can also be used on concrete, wood and composites, albeit with less resolution. It is a form of non-destructive testing . RED DYE PENETRATION TEST (RDP) Dye reentrant inspection (DPI), also called liquid reentrant inspection (LPI), is a widely applied and low-cost inspection method used to locate surface-breaking defects in all non-porous materials (metals, plastics, or ceramics). Reentrant may be applied to all non-ferrous materials, but for inspection of ferrous components magnetic particle inspection is preferred for its subsurface detection capability. LPI is used to detect casting and forging defects, cracks, and leaks in new products, and fatigue cracks on in-service components.

24. Principles DPI is based upon capillary action, where low surface tension fluid penetrates into clean and dry surface-breaking discontinuities. Reentrant may be applied to the test component by dipping, spraying, or brushing. After adequate penetration time has been allowed, the excess reentrant is removed, a developer is applied. The developer helps to draw reentrant out of the flaw where a visible indication becomes visible to the inspector.

25. MEASURING & INSPECTION

26. TYRE DEFECT GUAGE 1. Root wear 2. Sharp flange 3. Thin flange 4. Deep flange 5. Hollow tyre 6. Flat tyre (tyre condum)

27. TRACTION MOTOR

28. TRACTION MOTOR Traction motor refers to an electric motor providing the primary rotational torque to a machine, usually for conversion into linear motion (traction). Traction motors are used in electrically powered rail vehicles such as electric multiple units and electric locomotives, other electric vehicles such as electric milk floats, elevators, conveyors, and trolleybuses, as well as vehicles with electrical transmission systems such as diesel-electric, electric hybrid vehicles and battery electric vehicles

29. TURBO SUPERCHARGER

30. The diesel engine produces mechanical energy by converting heat energy derived from burning of fuel inside the cylinder. A turbocharger or turbo, is a gas compressor used for forced-induction of an internal combustion engine. Like a supercharger, the purpose of a turbocharger is to increase the density of air entering the engine to create more power. However, a turbocharger differs in that the compressor is powered by a turbine driven by the engine's own exhaust gases. The maximum rotational speed of the turbine is 18000/22000 rpm for the Turbo supercharger and creates max. Of 1.8 kg/cm2 air pressure in air manifold of diesel engine, known as Booster Air Pressure (BAP). Low booster pressure causes black smoke due to incomplete combustion of fuel. High exhaust gas temperature due to after burning of fuel may result in considerable damage to the turbo supercharger and other component in the engine.

31. TURBO SUPERCHARGER AND ITS WORKING PRINCIPLE The exhaust gas discharge from all the cylinders accumulate in the common exhaust manifold at the end of which, turbo- supercharger is fitted. The gas under pressure there after enters the turbo- supercharger through the torpedo shaped bell mouth connector and then passes through the fixed nozzle ring. Then it is directed on the turbine blades at increased pressure and at the most suitable angle to achieve rotary motion of the turbine at maximum efficiency. After rotating the turbine, the exhaust gas goes out to the atmosphere through the exhaust chimney. The turbine has a centrifugal blower mounted at the other end of the same shaft and the rotation of the turbine drives the blower at the same speed. The blower connected to the atmosphere through a set of oil bath filters, sucks air from atmosphere, and delivers at higher velocity. The air then passes through the diffuser inside the turbo- supercharger, where the velocity is diffused to increase the pressure of air before it is delivered from the turbo- supercharger.

32. MAIN COMPONENTS OF TURBO-SUPERCHARGER Turbo- supercharger consists of following main components:- 1. Gas inlet casing. 2. Turbine casing. 3. Intermediate casing 4. Blower casing with diffuser 5. Rotor assembly with turbine and rotor on the same shaft.

33. ADVANTAGES OF SUPER CHARGED ENGINES A super charged engine can produce 50 percent or more power than a naturally aspirated engine. The power to weight ratio in such a case is much more favorable. Better scavenging in the cylinders. This ensures carbon free cylinders and valves, and better health for the engine also. Better ignition due to higher temperature developed by higher compression in the cylinder. It increases breathing capacity of engine. Better fuel efficiency due to complete combustion of fuel

34. Defect in Turbochargers 1. Low Booster Air Pressure (BAP). 2. Oil throwing from Turbocharger because of seal damage or out of clearance. 3. Surging- Back Pressure due to uneven gap in Nozzle Ring or Diffuser Ring. Must change components of Turbocharger. Intermediate casing gasket. Water outlet pipe flange gasket. Water inlet pipe flange gasket. Lube Oil inlet pipe rubber o ring. Turbine end Bearing. Blower end Bearing. Chimney gasket. Rubber o Ring kit. Spring Washers. Lock Washer Rotor Stud.

35. COMPRESSOR

36. COMPRESSOR The compressor is a two stage compressor with one low pressure cylinder and one high pressure cylinder. During the first stage of compression it is done in the low pressure cylinder where suction is through a wire mesh filter. After compression in the LP cylinder air is delivered into the discharge manifold at a pressure of 30 / 35 PSI. Workings of the inlet and exhaust valves are similar to that of exhauster which automatically open or close under differential air pressure. For inter-cooling air is then passed through a radiator known as inter-cooler and than this compressed air passes to high pressure cylinder and stored in auxiliary and brake cylinder for brake application. Such as : BRAKES: Emergency brake (7kg from M.R) Auto brake (5kg from B.P) Guard brake (E.P+AUTO) Dead man brake 5kg Electric pneumatic brake 5kg

37. PIT WHEEL LATHE

38. INTRODUCTION Various type of wear may occur on wheal tread and flange due to wheel skidding and emergency breaking. Four type of wear may occur as follows:- Tread wear Root wear Skid wear and Flange wear For maintaining the required profile pit wheel lathe are used. This lathe is installed in the pit so that wheel turning is without disassembling the axle and lifting the loco and hence the name pit wheel lathe

39. Wheel turning Wheel turning on this lathe is done by rotating the wheels, both wheels of an axle are placed on the four rollers, two for each wheel. Rollers rotate the wheel and a fixed turning tool is used for turning the wheel.

40. PENTOGRAPH

41. PANTOGRAPH Pantograph is an apparatus which mounted on the roof of the electric train to collect power through contact with an overhead tension wire. It lift or down on the basis of wire tension. Typically a single wire is used with the return current running through the track. Device used to control it :- Servomotor (4.6kg/cm2) VCB/ABB WORKING SPECIFICATIONS: WORKING TIME (6-10)second but it takes 12 min. LEAKAGE TESTING 7kg

42. PANTOGRAPH PARTS : Base Lower arm Main spring Centre pedestal Balancing beam Longitudinal tube Steady link Steady tube Push rod Middle articulation assembly Upper articulation assembly Bow assembly Yog assembly Copper shunt Metalize carbon strip