To study and analyzing the wagon care of

Northern Indian Railway

Amity school of engineering and technology, Noida Uttar Pradesh
Mr.Syed Mujahid Azam
syedmujahidazam@gmail.com

Acknowledgement

I am very thankful to the Mr. Sharma Sir to give me such a wonderful opportunity of working
with them in the wagon care centre of Tughlakabad. I also want to thank Mrs. Daya Mam
from Baroda house to guide me through the entire process, if not for them working with
Indian railway wouldn’t have been possible.

I would also like to thank Mr. Prakash kamal for his sincere efforts in educating us about
the ways of the industry help me a lot. He meticulously taught me about the ultrasonic wave
testing. I am also very thankful to respected labour force of wagon care centre for their
sincere and diligent efforts in helping me along my journey in each and every possible way.

Due to the support of all such people I was able to effectively study and analyse the topic of
my summer internship.

Abstract: - This industrial training report titled as “WAGON MAINTENANCE AND

CARE” explain the various process, tasks and jobs that are executed in a systematic order to
perform the maintenance of wagon. This report also includes the various important testing
that are done on the wagon parts to find out that either they are fitting in safe criteria. It also
includes the primary structure and the maintenance scheduling of the wagon. This report also
contain the different types of wagons i.e. types of freight stock wagon and it is also stated the
important parameters of wagon such as dimensions of the wagons, parts of the wagon, etc.
One of the most important content that this report contains is braking system of the train more
specifically the air brakes and after that a new system of braking is introduced which is
independent on the maximum braking force (friction force) available between the train wheel
and rail track. The new system that apply brake on the train increase the overall braking force
that ultimately results in decreasing the stopping distance of the train.

Table of Contents: -
Topic Page No.
Introduction
Materials and methods
Results and Discussion
Implication for Future Research
Appendices
References

Introduction: -
Tughlkabad Railway Station is one of the five main railway stations of Delhi. It is known to
connect all the major Indian cities through Delhi. It is managed by Northern Railway zone of
Indian Railway. Before moving on our project, the facility gives us a detailed tour of various
department of administration and in the first week of internship, we tour the industry and find
out the administration of the wagon care center Tughlkabad.

The head of organization of the wagon care center, Tughlkabad is ADME/FR “Mr. Sharma

Sir”. After this, the administration is divided into two part, one is SSE /I/c and other is

SSE/PLC.
Indian Railways is headed by a seven-member Railway Board whose chairman reports to

the Ministry of Railways. Railway Board also acts as the Ministry of Railways. The officers

manning the office of Railway Board are mostly from organised Group A Railway Services

and Railway Board Secretariat Service. IR is divided into 18 zones, headed by general

managers who report to the Railway Board. The zones are further subdivided into 68

operating divisions, headed by divisional railway managers (DRM). The divisional officers of

the engineering, mechanical, electrical, signal and telecommunication, stores, accounts,

personnel, operating, commercial, security and safety branches report to their respective

DRMs and are tasked with the operation and maintenance of assets. Station masters control

individual stations and train movements through their stations' territory. In addition, there are

a number of production units, training establishments, public sector enterprises and other

offices working under the control of the Railway Board.

ABOUT LHB COACHES
LHB Coaches. Linke Hofmann Busch (LHB) coaches are the passenger compartments of
Indian Railways that have been developed by Linke-Hofmann-Busch of Germany (renamed
Alstom LHB GmbH in 1998 after the takeover by Alstom) and produced by Rail Coach
Factory in Kapurthala, India.
The first railway proposals for India were made in madras in 1832. The country's first
train, Red Hill Railway (built by Arthur cootto transport granite for road-building), ran
from Red Hills to the Chintadripet bridge in Madras in 1837.[7] In 1845, the Godavari Dam
Construction Railway was built by Cotton at Dowleswaram in Rajahmundry, to supply stone
for the construction of a dam over the Godavari River. In 1851, the Solani Aqueduct
Railway was built by Proby Cautley in Roorkee to transport construction materials for
an aqueduct over the Solani River.
India's first passenger train, hauled by three steam locomotives (Sahib, Sindh and Sultan), ran
for 34 kilometres (21 mi) with 400 people in 14 carriages on 1,676 mm (5 ft 6 in) broad
gauge track between Bori Bunder (Mumbai) and Thane on 16 April 1853. The Thane
viaducts, India's first railway bridges, were built over the Thane creek when the Mumbai-
Thane line was extended to Kalyan in May 1854. Eastern India's first passenger train ran 24
miles (39 km) from Howrah, near Kolkata, to Hoogly on 15 August 1854. The first passenger
train in South India ran 60 miles (97 km) from Royapuram- Veyasarapady (Madras) to
Wallajah Road (Arcot) on 1 July 1856.

The merits of LHB coaches

 LHB coaches are currently being manufactured at Kapurthala, as well as Rae Bareli.
 LHB coaches have the maximum permissible speed of 160 kmph (and not 200 kmph
as he stated.
 The coaches do not climb over each and crash because of a special type of CBC
(centre buffer coupler).
 It has more amenity fitting provided for the passengers.
 LHB coaches are approximately 2-meters longer than the conventional ICF type
coaches.
 Per meter length, weight of LHB coach is approximately “10%” lesser than the
conventional coach.
 Adaptation of latest design for improved ride comfort.
 Improved primary and secondary suspension for smooth and comfortable riding,
obtained by use of flexi coil spring.
 5 passenger emergency alarms per coach have been provided at following locations.

Coaches details of LHB.

COACH SHELL
 Stainless steel material.
o Sidewall & roof structural members in ferritic steel.
o Sidewall and end wall sheets of ferritic steel.
o Roof sheet & trough floor in austenitic steel.
o IRSM-41 steel for all other structural members.
 Structural joints o Inter-locking joints of vertical & horizontal members.
USE OF COMPOSITE MATERIALS
 “Alucobond” Lavatory Ceiling Panel & Aluminium Honey Comb Partition Panels.
o Improved aesthetics
o Very good surface finish
o Corrosion resistance
o Better rigidity

BOGIE DESIGN FEATURES

 Adaptation of latest design for improved ride comfort.
 Designed for operating speed of 160 kmph, tested at 180 kmph and has a potential
for operation up to 200 kmph.
 Structurally superior “y- frame” bogie construction making it lighter and yet
stronger.
 Improved primary and secondary suspension for smooth and comfortable riding,
obtained by use of flexi coil spring.
 Difficult to maintain dash-pot in ICF coach has been eliminated.
 ADME

SSE/ I/C SSE/PLC

SSE/T/DUTY SSE/ROH SSE/ Sick Line SSE/Store SSE/ ICD SSE/CONTRACT

Proper batch A B
Batch I/C A Batch SSE/Tech
c

Bat h I/C B batch

SSE/ O/L Batch

Batch I/C C/Batch

Organization chart

ADME Assistant Divisional Mechanical Engineer

SSE/I/C Senior Section Engineer,
SSE/PCV Senior Section Engineer, Passenger Wagoning
Vehicle
SSE/CONTRACT Senior Section Engineer, contract
SSE/TECH Senior Section Engineer, technician
SSE/T/DUTY Senior Section Engineer,
SSE/POH Senior Section Engineer, Periodic Overhauling
SSE/SICK LINE Senior Section Engineer, sick line engineer
SSE/STORE Senior Section Engineer, store
SSE/IOC Senior Section Engineer, Indian Oil Corporation
SSE/O/L BATCH Senior Section Engineer,
BATCH I/C A BATCH
BATCH I/C B BATCH
BATCH I/C B BATCH
PROPER BATCH A, B, C

Training schedule of industrial training provided on 01/06/2019 to 28/06/2019

Date Schedule Training Engineers
01.06.2018- Washing line (Non Rajdhani) Mr. Manmohan Singh
 08.06.2018
09.06.2018- Sick Line Mr. Prakash Kamal
14.06.2018
15.06.2018- Train Duty Mr. G. L. Meena
20.06.2018
21.06.2018- Linen Management Mr. M.T.D. Murthy
24.06.2018
25.06.2018- Washing Line (Rajdhani) Mr. Satbir Singh
28.06.2018

Indian railway is one of the largest means of transport in India. 20,000 passenger train and
9,200 freight trains run daily on Indian railway tracks and all that is governed by Indian
railway. There are 22 million people travel by Indian railway that makes around 8.1 billion
every year. Indian railway was setup in 1845. It is one of the biggest companies that is owned
by the government of India. It came under the controlled of a separate ministry of India i.e.
“ministry of railway” that manage the railway of India. It is also one of the largest
contributors to Indian economy with a net income of approximate Rupees 60 billion. The
budget of Indian railway is Rupees 4,587 crore for the year 2019-2020. Indian railway is now
fourth largest network of railway by having a total of 115000km of track and it contains more
than 7112 stations. It has of 22 trains of Rajdhani Express which connect New Delhi to some
important cities, 26 pair of Shatabdi Express,450 pairs of Superfast and 7421 local
(EMU/DMU) trains. Indian railway has the largest number of employees with a total of more
than 1.3 million employees. It has helped the economic life of country and helped in
accelerating the development of industry and agriculture and bind the social, cultural &
economic fabric of country and removing the distance barrier for its people.
There are total 18 division of Indian railway as per the geographical zone of India and
Northern railway is one the 18 division of Indian railway. The Northern Indian railway zone
is consisting of five divisions and those division are named as
1. Ambala division
2. Delhi division
3. Ferozepur division
4. Moradabad division
5. Lucknow division
Each railway zone is controlled by a general manager (GM) who gave information directly to
the railway board. The zones are classified into the division that is control by the divisional
railway manager (DRM). The divisional officers, mechanical engineer, electrical engineer,
signal and, personnel, operating, commercial, security and safety branches, report to the
respective divisional railway manager.

We study the different parts of the wagon and try to use the tools which is necessary in the
wagon service center. There are a lot of small parts of the wagon which is kept in the store
house as a sample and further studying.
Angle Cock- To cut and open pressure to adjacent wagon. Defective seal causes leak.
Rubber Bonded Centre Pivot Washer- Fitted in Centre pivot and secured by shackle lock.
Ensure properly fitted, should not be broken.
ATL- Locking arrangement for container. Ensure 100% working during service.
MU Washer- Seals air pressure between two palm ends of the air hose cooling. Torn,
deformed MU washer causes air pressure leakage should be changed.
Torsion Spring Steel- Provides torque for automatic operation of twist lock should not be
broken, and weak.
Torsion Spring Rubber- Provides torque for automatic operation of twist lock should not be
broken.
Shackle Lock- Holds wagon body with bogie through pivot pin, Ensure properly fitted with
pivot pin.
‘Z’ Plate- In loaded condition LSD plunger hits this plate should provide perfect horizontal
platform for LSD plunger and gap between LSD plunger and ‘z’ plate should be within
prescribed limit in empty condition.
Side Bearer Spring- Wagon body weight is transferred to bols and breakage and free height
less then 119mm and to be allowed.

Brake block- Clasping wheel tread while braking. Thickness should be more than 10mm
during service.
Bottom Liner- Protect the bolster wear. Not to be allowed after 2 mm wear.
Side Bearer Seat- 90% wagon body weight transferred to side bearer spring, worn and broken
not to be allowed.
EM Pad- Protects shock to CTRB, Plate shifted and bond failed not be allowed in service.
Side Bearer Housing- Houses side bearer springs Worn and broken not to be allowed.
CCSB (constant contact side bearer)-
Reducing Valve- Fitted before either of the two LSDs to reduce the pressure to 4 kg/cm 2
working at 4 kg/cm2 pressure must be ensured.
Floating lever- Transfer braking force from pull rod to brake beam, not to be allowed bent or
with worn out bush.
Pocket Liner- Guiding brake beam and protect side frame wear. Thickness should be more
than 2 mm during service.
Wide jaw Adapter- Holds and CTRB and transfer the wagon load to track though side frame
and EM pad should not be allowed with wear on any mating surface and part broken.
The target of this week is to visit the industry and to look after the instrument of the wagon
care. After this, our target is to catch the technique of industry’s worker how they are opening
the wagon of the whole parts and how they are separating the wheels from the body of
wagon.

We cared the instrument of the industry by the storing the tools and important instrument in
the store house and we cleaned the tools using lubricant and oil. We have watched the
workers how they are working on the opening of the wheels. First of all, they are opening the
spring from the wheel, and after this we found out, is spring is usable or not.
Primary suspension in icf bogie is through dashpot arrangement
The dashpot arrangement consists of a cylinder and the piston
The axle box guide is welded to the bogie frame
In the primary suspension mainly, we have a spring and a dashpot to provide damping
arrangement so regulate refill of oil and changing of oil being done in the workshop
indian Railway (IR) runs more than 20,000 passenger trains daily, on bot, from 7,349 stations
across India. The trains have a five-digit numbering system. Mail or express trains, the most
common types, run at an average speed of 50.6 kilometres per hour (31.4 mph) In the freight
segment, IR runs more than 9,200 trains daily. The average speed of freight trains is around
24 kilometres per hour (15 mph)
Sick line is the workshop for the major and periodical maintenance of the coaches it consists
Of modern facilities like pit for working under frame and crane for separation of coach and
bogie for repair of all types of defects.
1.Train for the secondary maintenance are given at least 2 hrs on the washing line
2.Linen and pantry car provision
3.Washing and cleaning of coaches
Knuckle- It is used to couples two wagons through CBC. Any mating surface should not
worm.
Push Rod- transfers braking force from one equalizing lever to another equalizing lever. Bent
and welding failed not be allowed.
Lock Lifting Rod- It operates the locking arrangement of CBC should not be bent or broken.
EPR- It is attached in between equalizing lever and body frame should not be allowed broken
and bent.
LSD and Parts- Pneumatic signal sent when wagon is in loaded condition. Leakage is not
allowed.
LSD- Pneumatic signal sent to DV when wagon is in loaded condition, leakage is not
allowed.
CBC (Centre Buffer Coupler)-The coupler is opened manually using the coupler operating
rod and is closed automatically when the couplers on adjacent vehicle are mated. The coupler
automatically locked when fully mated. It is generally used in LHB/ Hybrid Coaches.
 Arranged Tools & parts in the tool rooms

Materials and Methods: -

Ultrasonic testing (UT) is a family of non-destructive testing techniques based on the
propagation of ultrasonic waves in the object or material tested. In most common UT
applications, very short ultrasonic pulse-waves with center frequencies ranging from 0.1-
15 MHz, and occasionally up to 50 MHz, are transmitted into materials to detect internal
flaws or to characterize materials. A common example is ultrasonic thickness measurement,
which tests the thickness of the test object, for example, to monitor diameter of the wheels.
In ultrasonic testing, an ultrasound transducer connected to a diagnostic machine is passed
over the object being inspected. The transducer is typically separated from the test object by a
couplant (such as oil) or by water, as in immersion testing. However, when ultrasonic testing
is conducted with an Electromagnetic Acoustic Transducer (EMAT) the use of couplant is
not required.
In Tughlkabad wagon Care Centre there is two cranes available for lifting of coaches in order
to do IOH & POH.
Before lifting a coach, the following components should be removed, disengaged or
disconnected: -
(i) Dynamo belt on the axle pulley in case of underframe mounted dynamos and
disconnection of electrical connection from junction box on alternator in case of
bogie mounted alternator.
 (ii) Lavatory chute, if suited over the bogie.
(iii) Brake pull rod from bogie brake rigging.
(iv) Centre pivot cotter.
Axle box safety straps.

Results and Discussion: -

We analysis the theory of chip formation and how many types of chip formation takes place
during machining. We have also target to study the material used in the design of wheel and
wagon. We want to find the types of machine used in the machining process such as lathe
machine, drilling machine and automatic machining process.
Chip formation is part of the process of cutting materials by mechanical means, using tools
such as saws, lathes and milling cutters. An understanding of the theory and engineering of
this formation is an important part of the development of such machines and their cutting
tools.
 Continuous chip. High back rake angle. Continuous chip obtained when cutting...
 Continuous chip with built-up edge. Similar to the continuous chip except the built-up
edge at...
 Discontinuous chip. Low stiffness of machine tools that allows vibrations.

Lathe Machine
 Continuous Chip formation

Continuous & Discontinuous chip

Working Wheel or damaged wheel
Finished Product
Conclusion(s) & Recommendations: -
After having six weeks of long internship in wagon care centre in tughlakabad I have learned
a lot of new things that is difficult to learn from any books. It was a very productive and
learning environment there and I have learned the following new things
1. I participated in a tour of the department and shop floor. I learned about
the security and various safety measures that were taken into account
while I was present in the industry. I saw the maintenance line on which
wagons were being washed for approx. 20 minutes and dismantled using
overhead crane. I went to the tool room and saw different type of
calibrator tools, cutting tools and measuring tools.
2. I learned about one of the most important machines on the shop floor that
was lathe machine. The lathe machine working on shop floor was a type of
semi – automated machine in which four jaw chuck was used and the lifting
as well as alignment of work piece was done by the hydraulic lifter. I saw the
whole process of turning of the wheel on the lathe so that it would have
better grip on the track.
3. I toured around one of the most important, critical and costlier machines
that was X-ray inspection machine. In that machine a set of wheels was lifted
by a hydraulic lifter and the operator tight the set of wheel in the inspection
machine and the machine test the wheels and gave output. Based on that
output it was decided that weather there is any internal crack in the wheel or
not.
4. I learned about the braking system of the train. I took various lectures
about the braking system of the train. I learned about the working of both air
and vacuum brakes. I learned about the traction force as well as braking
force of engine and wagon that was very essential for the study of brakes. I
saw the whole process of removing of the worn out braking pad and the
installation of new braking pad and I introduce a new braking system for the
railway.