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PRESENTATION ONCARRIAGE AND WAGON SHOP
PRESENTED BY :AJEET KUMARROLL NO- 1112240014
ABOUT CARRIAGE AND WAGON WORKSHOP
• The Alambagh workshop, near Lucknow, was set up in 1865 by the Oudh and Rohilkhand Raiilway. It started off doing minor maintenance and periodic overhaul of coaches and wagons, and eventually became one of the top workshops engaged in overhaul, repair, and restoration of carriages and wagons. Today the workshop specializes in the new high-speed coaches (LHB Alstom, IR20/IRY, etc.), air-conditioned coaching stock, etc.
The Basic Data for workshop are as under• WORKSHOP AREA = 204684 Sq. Mtrs.• COVERED AREA = 72595 Sq. Mtrs.• POWER CONSUMPTION = 14666 KWH/day• WATER CONSUMPTION = 1575000 Ltrs./day
CONTINUED….
Major Shops
Train Lighting
AC Deluxe
Carriage Fitting
Carriage Building
Heavy Corrosion Repair
Bogie Lifting
Wheel Shop
Spring Shop
Common Shops
Minor Shop Major Shop
Paint Shop Mill Wright Shop
Road Transport Shop New Machine Shop
Yard Carriage Shop Carpentry Shop
Role of C&W workshop in Railways
A. Related with Open Line working :-
i) To ensure and co-operate in safer running of rolling stock.
ii) To attend required schedule maintenance & running repairs of rolling Stocks till the stocks are again due for P.O.H.
iii) To assist in time running of trains to maintain the punctuality.
B. Related with Work -Shop working :-
i) To attend Periodical Overhauling of Rolling Stocks.
ii) To adopt required modifications.
iii) To maintain proper records of all the rolling stocks running in Indian Railways.
CLASSIFICATION OF ROLLING STOCK
• Rolling Stock: - It is a term used for the stocks of coaching, freight (Goods) & Locomotive.
• Coaching Stock: - All coaching vehicles including self propelled units such as rail cars, electrical multiple unit, luggage & brake van fit to run with coaching stock are known as coaching stock.
• Goods Stock: - All goods stock other than coaching stock whether attached to passenger or goods trains are known as goods stock.
Vehicle: - It is a term used only for coaching stock. There are two types of Coaching Stock.
1) Passenger coaching vehicle (PCV): - A vehicle in which whole or partial portion is being utilized for carrying passengers.
2) Other coaching vehicle (OCV): Saloons, inspection cars, medical cars, tourist cars, parcels & horse van, composite luggage Power Cars, Pantry Cars & brake van are known as OCV.
Types Of Coaches
• ICF: Integral Coach Factory, Perambur (Chennai) & Rail Coach Factory, Kapurthala (Punjab)
• LHB COACHES: LHB body with FIAT bogie (Linke Holfmann Busch – German) Maximum Permissible Speed 160 kmph
.
Hybrid Coach: LHB Body on Modified ICF Bogie – Running in same of the Duranto Rake
Loco- Brief Data
Weight of complete loco-123 tons.
Weight of Loco body is 73 tons.
Weight of complete bogie is 25 tons each.
Load exerted per axle is 20.5 tons.
Weight of Traction motor is 3.80 tons.
Wheel set with gears is approx. 2.15 tons.
Manufacturing units
Coaches- Integral Coach Factory,Perambur,Chennai.
Rail coach factory, Kapurthala,Punjab.
Wagons-BEML(Bharat Earth Movers Limited).
Diesel components Workshop at Punjab.
Major workshops-
DLW(Diesel Loco Workshop) at Varanasi.
Chittaranjan Loco Workshop.
BHEL also manufacture on contract basis.
RDSO is the authentification Unit of railways.
TRAIN MAINTENANCE
Washing line :-
after every 2500 km
Sick line :-
Schedule “A” maintenance- 1 month
Schedule “B” maintenance- 3 months
IOH- 9 months or 2,00,000 km
POH- 18 months or 4,00,000 km
Platform Train Duty:-
on starting & ending stations
BRAKE TESTING IN WASHING LINEBrake testing is carried by using RTR (rack test rig)Rack testing rig is capable of testing full train (up to
24 coaches) at a time.
SECONDARY MAINTENANCEThe trains for the secondary maintenance are given at
least 2 hrs on the washing lineLinen and pantry car provisionsWashing & cleaning of coachesMaintenance of AC of coaches
PRIMARY MAINTENANCEThe trains for the primary maintenance are given at least 6 hrs
at the washing line in addition to secondary maintenanceOil in hydraulic dash potsWheel profiles are visually examined and gaugedpest control treatmentAxle box is examined for grease oozing out from rear coverBrake blocks & piston stroke checked & changed
COACH MAINTENANCE
In coach maintenance generally these work being done
1. testing/maintenance of air conditioner.
2. Maintenance of other electrical circuits like fan light
etc.
3. Buffer maintenance.
4. Brake testing by S.C.T.R.
BUFFER MAINTENANCEBuffers are the horizontal shock absorbing parts with
coupling the adjacent coaches of the train so need regular changing of shock absorbing rubber pads.
BRAKE TESTING
Here S.C.T.R. use for testing of brake and its cylinder acts as the
main reservoir.
There are two pressure potentials i.e. 5kg/cm2 in brake pipe and
6kg/cm2 in feed pipe.
SEPARATION OF COACH & BOGIE After watching the inspection list if bogie needs
repair like filling of oil or changing of brake shoe etc. then bogie is separated from the coach by lifting through a crane
MAINTENANCE OF BOGIE
Maintenance processes done on the bogie such as replacement of the Brocken, wear out parts, replacement of pins and brake shoe, filling of oil in the suspensions, lubrication of different parts, tightening of different screws and bolts and change of axle & wheels if required.
MAINTENANCE OF SUSPENSION
In primary suspension mainly we have a spring and a dashpot to provide damping arrangement so regular refill of oil and changing of oil being done in the workshop
CHANGE OF DEFECTIVE WHEELS
Wheels of train are subjected to a no of defects i.e. reduce in the dia. of wheels, Reduce in size of flange, break of bearing in axle box
BRAKE MAINTENANCE
Brakes are the most important part of a train. The maintenance of brakes consists of change of brake blocks, adjust stroke length, change of brake cylinder, leakage in brake system etc.
AXLE BOX FEELING
After the train come to halt, all axle boxes are felt within 20 minutes. The temp. of axle is checked by touching with hand
Temp. is found high then it is checked by the temp. gun which gives exact temp.
If this temp. is found more than 30 degree than atm. temp. then the cause is inspected and coach is sent to workshop
COTINUED…
i) Quick Coupling in case of Brake Van.
j) Automatic empty load change over device in case of BOBR/BOBRN Wagons.
Use new rubber items for joints between pipe and equipment irrespective of condition of old items.
xiv) Properly secure nut and bolts of joints between pipe and equipment.
xv) Examine all pipe and pipe fittings and brackets and properly secure them.
Pipes should not be loose inside the pipe clamps.
xvi) Fit following APD :
a) Additional APD of DV.
b) APD of DV.
c) APD of Angle Cock
xvii) Fit overhauled Hose Couplings at both ends of Brake Pipe.
xviii) PAINTING
All items shall be painted black as per standard practice.
PERIODICAL OVERHAUL OF WHEEL ASSEMBLY
i. The dust shield should be examined, every time the axle box is repacked during POH. If found worn, torn, or if it has lost its stiffness, it should be replaced.
ii. Axle boxes should be examined and inspected on open lines for defects.
iii. The elongated/oval cut holes on face plate should not allowed. Proper
riveting of the face plate to be done with axle box.
iv. Bearing brass to be examined and repaired.
v. Repair of the journal to be done.
vi. Periodicity of repacking and oiling .
vii. Proper attention must be paid to the examination and riveting of the face plate at the time of POH in workshop.
ix. Procedure for white metalling to be done.
x. Examination and maintenance of Axle, wheels and tyres should be done.
Difference Between IOH, POH & NPOH Sl.No IOH POH NPOH
1 It stands for intermediate overhauling.
It stands for periodic overhauling. It stands for non periodic overhauling.
2 IOH of coach is attended after 9 months of POH.
POH of Passenger carrying vehicle M/Exp -18 months,
Time Period is not fixed for any vehicle for NPOH
3 IOH of coach is allowed in sick line where facility to lift the coach is available.
POH is allowed in nominated workshops only.
NPOH is done only in workshop or in nominated major sick line.
4 During IOH all the parts of under gear thoroughly examined and replaced if necessary.
At the time of POH all parts of under gear are dismantled and should be replaced if there is any wear and tear.
Only indicated defects & safety items are attended.
5 At the time of IOH painting of coach is not necessary, only required places are touched up.
Painting of whole coach is necessary. Complete painting of coach is not necessary, only required places are touched up.
6 Profiling of wheel is necessary
Profiling of wheel is necessary. Profiling of wheel is on need based.
BOGIE-A brief description
4 wheel set is known as Bo-Bo type.
6 wheel set is known as Co-Co-CO type.
Former type is used as
COACH
GOODS WAGON
• Later type is used as LOCOMOTIVE
Comprises of bogie frame and the loco weight
mounted on it.
EQUIPMENTS in a Bogie
It comprises the Bogie
frame.
The bogie frame has the
Axle and wheel
arrangements.
The SUSPENSION
system.
The BRAKING system.
MAINTENANCE/INSPECTION
Various periodic inspections are made to
ensure proper functioning of the LOCO
• TRIP INSPECTION• MONTHLY INSPECTION• TWO MONTHLY NSPECTION• FOUR MONTHLY INSPECTION• YEARLY INSECTION• POH INSPECTION
POH inspection
It is accomplished either after 9
years or 9 lacs km.,whichever is
earlier.
Dismantling of bogie is done.
Parts are cleaned in acidic
solution for about four hours.
Axle box is checked for heating
up.
Evidence of cracks and other
defects are replaced.
Bogie Manufacturing
Initially done by Casting.
Generated cracks
Rate of success was 60 %.
replacement was difficult.
Fabrication is done now a days
Welding and Oxycutting is done.
Rate of success is 80 %.
replacement of parts is easy.
Bogie-Fuel Tank
Capacity of fuel tank- 5000 litres.
At full load, consumption is 325-365 litres/hour.
Average fuel consumption is 45 litres/hour at
standby mode.
Approximately, 5.5 litres/km.
bogie
A bogie is a wheeled wagon or trolley. In mechanics terms, a bogie is a chassis or framework carrying wheels, attached to a vehicle.
Usually the train floor is at a level above the bogies, but the floor of the car may be lower between bogies.
Bogies serve a number of purposes:
1. To support the rail vehicle body
2. To run stably on both straight and curved track
3. To ensure ride comfort by absorbing vibration, and minimizing centrifugal forces when the train runs on curves at high speed
Usually two bogies are fitted to each carriage, wagon or locomotive, one at each end. Most bogies have two axles as it is the simplest design, but some cars designed for extremely heavy loads have been built with up to five axles per bogie.
Key components of a bogie include:
1. The bogie frame itself.
2. Suspension to absorb shocks between the bogie frame and the rail vehicle body. Common types are coil springs, or rubber airbags.
3. At least one wheel set, composed of an axle with a bearings and wheel at each end.
4. Axle box suspension to absorb shocks between the axle bearings and the bogie frame.
5. Brake equipment. Two main types are used: brake shoes that are pressed against the tread of the wheel, and disc brakes and pads.