SUMMER TRAINING PRESENTATION

INDIAN RAILWAYS CARRIAGE WORKSHOP MATUNGA

AMIT YADAV
B-TECH MAE
V SEMESTER

INDIAN RAILWAY

Railways were first introduced to India in the year 1853 from MUMBAI
to THANE.

In 1951 the systems were nationalised as one unit, the Indian

Railways, becoming one of the largest networks in the world.

By 1875, about 95 million were invested by British companies in

India guaranteed railways. By 1880 the network had a route mileage
of about 14,500 km (9,000 mi), mostly radiating inward from the
three major port cities of Bombay madras and Calcutta.

COACH REPAIR WORKSHOP MATUNGA

ACTIVITIES

TARGET

POH of Mail/Express Coach & POH of Passengers Coach

147 coaches per month including 28

AC Coaches

Heavy Corrosion Repair

14 per month

POH of EMU Coach

60 coaches

EMU Rehab-Mid-Life & EMU RehabEnd-Life

8 Coaches per month

TOTAL CAPACITY

243 PER MONTH

MACHINARY AND PLANTS

The Workshop is equipped with 44 EOT Cranes, 3 Surface Traverses

and 19 Air compressors, in addition to another 700 machines and
more than 10 equipments and cleaning plants.

The workshop is provided with a captive internal transport section

which caters to all the material transportation needs, within and
outside the Workshop

THE MAINTENANCE SCHEDULES AND THE OVERHAULING PERIODS

1. Trip schedule- After every trip by primary maintenance depot.

2. Schedule A - Monthly (1 month )

3. Schedule B - Quarterly (3 months )

4. IOH 9 months

5. POH 18 months

Periodic overhauling is the best available process of maintenance of coaches in India. This generally
operated after 18 months after the manufacturing or the previous periodic overhauling done in any
workshop. This undergoes a huge process of lifting the coach, isolating the all parts, and changing or
replacing the necessary or damaged parts. In other words this is the process of renewing the coaches.

WHEEL PROFILE

DEFECTS
Thin Flange :- When the flange thickness reduces from 28.5 mm to
16 mm or less, then the flange is called thin flange.

Sharp Flange :- When the radius given at the tip of flange is worn out
from 14.5mm to 5 mm or less is called Sharp Flange.
Thin Tyre :- If the remaining thickness of tyre is less than 25 mm, it is
called thin tyre.

Hollow Tyre :- If the groove on the wheel tread is up to 5 mm or more,

it is called Hollow tyre

COACH

AXLE

It is the main long cylindrical bar on which bogie are fixed with the help of bearings. This is made of
steel as above. Each axle contains 2 wheels, the brake cylinders are also attached to it and in case of
LHB coaches, the braking discs are fixed on to the axle.
The axle mounted brake disc consists of a gray cast iron friction ring and a
cast steel hub, connected by means of radially arranged elastic resilient
sleeves which are secured in the hub by means of hexagon screws. The
friction ring is manufactured as a solid component or in a split version. In the
latter case, the two halves are held together by two tight fit screws.

AIR BRAKE SYSTEM

The brake system in which compressed air is used in the brake cylinder for the application
of brakes is called air brake system.

WORKING PRINCIPLE

The different processes involved in working :-

a) Charging

b) Application

c) Release

Under normal conditions the Brake pipe is charged with 5kg/cm2 from the loco. The control
reservoir and the Auxiliary reservoir are charged with 5 kg/cm2 and 6 kg/cm2 respectively
from BP through Distributor valve.

When the brake pipe is charged at 5 kg/cm2 the brake cylinder is connected to exhaust
through distributor valve in order to keep the brake in released position fully.

Whenever the brake pipe pressure is reduced below the CR pressure, the DV connects the
auxiliary reservoir with the brake cylinder and the air from AR is sent into the brake cylinder to
apply the brake.

Whenever the brake pipe pressure is equal to CR pressure the DV disconnects the BC from AR
and in turn connects the BC with Exhaust for the release of brakes fully.

BOGIE FRAME
The frame is made up of two longitudinal components
(1) connected by two cross-beams
(2) which also support the brake units.
The various supports which connect the
different bogie components are welded to the frame.

WINDOW UNITS
The sealed window units consist of 8.4 mm outer glass and 4 mm inner glass with 6 mm
Argon gas filled.
Argon is an inexpensive, non-toxic, odorless gas .
It increase sound proofing characteristics of the
window.
Minimizes heat exchange through the window.
Argon will not corrode the window material.
This type of windows can even block ultraviolet rays.

THANX FOR THE TIME

ANY QUERY