INDEX

S.N Schedule Date

from to
1 Store 22-06-23 05-07-23
2 Washing Line 06-07-23 09-07-23
3 Linen Management 10-07-23 12-07-23

4 Machinery & Plant 13-07-23 15-07-23

5 Sick Line 16-07-23 18-07-23
6 Train Duty 19-07-23 20-07-23
 Indian Railways: An Introduction

The history of Indian Railway dates back over 160 years as the first proposal was shared in 1832 and the
first train ran on 16 April 1853. Indian Railway operates the fourth-largest network in the world spanning
over 1.2 Lakh km across the country. With over 14 Lakh employees, it is the world’s seventh-largest
employer in the world following the Defence Department of the US, the Chinese Army, Walmart, China
National Petroleum, State Grid of China, and British Health Service.

Benefits of Indian Railways: -

Indian Railways is an essential part of India as it plays a major role in the life of the public. It is a
preferable mode of transport due to many reasons. Here are some benefits of carrying loads and
passengers through Indian Railways.

It is the cheapest and safest mode of transport as compared to other means of transport such as
airways, roadways, etc.

Also, the chances of breakdown and accidents are least as compared to other modes of transportation

There is no effect of weather on goods such as rain, fog, etc.

Indian Railway is a better mode of transportation because it has fixed schedules and routes

As per the companies, it is the best way to transport goods for long-distance traffic

The carrying capacity through Indian Railways is immensely large and moreover, there is flexibility to add
a few loads by adding more wagons.
Indian Railway History Facts -
To help students refresh their minds about the Indian Railway History, we have mentioned major facts
about it. This will help you recall important facts so you have them at your fingertips. Tabulated below
are some interesting facts about Indian Railways that every aspirant must know!

Total zones of Indian Railway 19

Indian Railway Slogan Lifeline of the Nation
The train that operates between Pakistan and India Samjhauta Express
The train that operates between India and Maitree Express
Bangladesh
World’s longest Railway platform Gorakhpur (1,366 meter)
India’s oldest working locomotive Fairy Queen
Total Railway Museums in India 8 (Delhi, Pune, Mysore, Kanpur, Kolkata, Ghum,
Chennai, Tiruchirappalli)
First Computerized Reservation in India started from 1986 in New Delhi
Indian train with a status of World Heritage Status Darjeeling
given by UNESCO
Total number of passengers that travel through Around 2.5 crore
Indian Railway
Longest train route in the Indian subcontinent Dibrugarh Kanyakumari Vivek Express
The fastest train in India New Delhi to Bhopal Shatabdi Express (Max. speed 150
KM/hr.)
Slowest train in India Metupalayam Ooty Nilgiri (Passenger train)
Railway station with the longest name Venkatanarasimharajuvaripeta Railway Station
Railway station with the shortest name IB, near Jharsuguda in Odisha and Od, near Anand in
Gujarat
Highest Railway Station in India Ghum Railway Station in West Bengal
Longest Railway Bridge in India Vallarpadam Bridge, Kerala with a total length of 4.62
KM
Longest Railway Tunnel in India Pir Panjal Railway Tunnel in Jammu & Kashmir with a
total length of 11.2 KM
The train which has most stops Howrah – Amritsar Express 115 halts
Most powerful locomotive engine Electric Locomotive WAG-9
The busiest station in Indian Railways Vijayawada Junction (247 unique trains)
Total number of trains run on daily basis 12,000 passenger trains and 7,000 freight trains (a total
of 19,000 trains)
Class of Accommodation in Indian Railway 1-AC, 2-AC, 3-AC, 3-AE, EC, CC, FC, SL, 2S, II-UR
Highest earning zone Northern Railway (120 to 125 Millo
State which has highest per capita rail route
State which has the lowest per capita rail route
Railway Station which is built on 2 states
Total number of Freight trains run every day
Total load carried every day
Average speed of freight trains in India
Most powerful freight locomotive of Indian Railways
International freight services link between
Freight Corridor with the highest traffic
Container Railway Freight traffic is managed by
Guinness Book of Records for having the world’s
largest Route Relay Interlocking System is taken by
The first woman to become Railway Minister
Railway budget of 2020-21
Freight Earnings in 2020
Passenger Earnings in 2020
ORGANIZATION STRUCTURE OF INDIAN RAILWAYS -
Andhra Pradesh (0.1 metre/ person)
Kerala (0.03 metre/ person)
Navapur Railway Station (one half of the station is
Gujarat and other half in Maharashtra)
9,200
1,110
24 Km/hr
WAG-12 (Generates a 12,000 Horse Power)
Birgani in Nepal and Raxaul of Bihar
Golden Quadrilateral Freight Corridor with a total of
55% freight traffic
Container Corporation of India (CONCOR)
New Delhi Railway Station
Mamata Banerjee
Rs 72,216 crore (US $10.33)
US $16.24
US $7.25
 Organistaion

India Level Zone Level Division Level Depot Level

Railway
GM DRM CDO/AEE
minister

Ministry of
AGM ADRM SSC JE
state

CRB CME/CEE SEN. DME TECH 1

Member of
CRSE AME TECH 2
rolling/shaft

Member of
DCM SSC JE TECH 3
electrical

Member of ASS. TECH/

AME
staff CNW

Member of
SSC JE
finance

Member of
infracture

DELHI NDLS
DEPOT
HNZM - My training is here.
MERATH
OLD DELHI
ZIND
SARAI ROHILA
GAZIABAD
ZONES OF INDIAN RAILWAYS –
Railway Zones in India- The Indian Railways is one of the largest rail networks in the world, With
approximately 67,000 kilometers of track and more than 23 million daily passengers.
To manage this massive transportation system the Indian railway is divided into several zones.
Each zone of the Indian railways is responsible for a particular geographic region. These railway
zones are an essential component of the Indian Railways.

No of Zones Railway Zone Headquarters

1 Central Railway Mumbai
2 Konkan Railway Navi Mumbai
3 Metro Railway in Kolkata Kolkata
4 Northern Railway Delhi
5 North Central Railway Prayagraj
6 North Eastern Railway Gorakhpur
7 Northeast Frontier Railway Malegaon
8 North Western Railway Jaipur
9 Eastern Railway Kolkata
10 East Central Railway Hajipur
11 East Coast Railway Bhubaneshwar
12 Southern Railway Chennai Central
13 South Central Railway Secunderabad Junction
14 South Coast Railway Visakhapatnam
15 South Eastern Railway Garden Reach, Kolkata
16 South East Central Railway Bilaspur
17 South Western Railway Hubbali
18 Western Railway Mumbai
19 West Central Railway Jabalpur
 Depot
(Coaching)

Primary depot Secondary depot

(Nominated (Terminated
trains - 4hrs) trains - 6hrs)
Facilities of Depot –

 Training duty – Rolling IN & Rolling OUT, BPC, Safe run to

Examination…etc.

 ACWR – Its means Automatic Coaching Washing Plant, that provide

automatic washing of external parts of coaches

 Sick Line – store, SL working, AC & Non-AC Coaches, Trolley

Maintenance , spl lifting, Air Brake Testing, Wheel, Axle Box, Springs,
fitments, welding, pipe fitting….etc

 CNC Lathe Machine – Use in Railways depot to remove Wheels defects.

 Linen Management – Linen distribution, Linen & Transportation….etc

 Schedule 1
Stores & Materials Management

Introduction Objective of Material Management: -

For running any industry or business, we need a number of resources. These resources are popularly
known as 5M's of any Industrial activity i.e.

a. Men
b. Machines
c. Materials
d. Money
e. Management

Objectives Of Materials Management

The objectives of integrated materials management can be classified in two categories;

 Primary
 Secondary

Primary Objectives: Following may be identified as primary objectives which are to be achieved.

(a) To purchase the required materials at minimum possible prices by following the prescribed purchase
policies and encouraging healthy competition.

(b) To achieve high inventory turnover i.e. to meet materials requirement of the organization by keeping
low average stocks so that the capital locked up in materials is turned over a large no of times.

(c) To incur minimum possible expenditure on administrative and other allied activities related to
purchase of materials and also to keep the materials in stock till they are finally delivered to the users.

(d) To ensure that continuity of supply of materials to the users is maintained by avoiding out of stock
situation.

(e) To supply materials of consistent quality i.e. of quality which meets user specification and is fit for
service.

(f) To keep the wage bill of the department low by ensuring proper distribution of work among staff and
not employing surplus staff.
(g) To maintain good relationship with the suppliers of materials and also develop new suppliers for the
products for which reliable suppliers do not exist.

(h) To ensure training and development of personnel employed in the department so that good
industrial relations are maintained.

(i) To maintain proper and up-to-date records of all stores transactions and purchases.

Secondary Objectives:

(a) To assist technical/design department in developing new materials and products which may be more
profitable to the organization.

(b) To make economic 'make or buy' decisions.

(c) To ensure standardization of materials

(d) To contribute in the product improvement.

(e) To contribute in the development of inter departmental harmony.

(f) To follow scientific methods of forecasting prices and future consumption of materials.

General Classification of Stores: -

Stores

Stock items - Non Stock items

Regularly used - Not Regularly
items used items
Stock items - Stores Department on Indian Railways is required to give a service to various
departments by making thousands of items available to their indenters as and when required. To give
this service we have to maintain stocks of a large number of items called as "Stock items"

Non-stock items - which are not frequently required or are of one-time requirement, no stocks are
maintained. These items are purchased as and when required to meet specific demands and are called
as `non-stock items.

Codification Of Stores –
In order to recognize every item distinctly, all standard items being used on Railways, have been allotted
a code number, which is also known as Price List (PL) No.

We can have three types of codification systems;

 Fully significant,
 Semi-significant
 Non-significant

 In fully significant system, all the digits of the code signify some property of the material while in a non-
significant system, digits have no significance and one cannot guess anything about material by seeing
only code no. Obviously if we have large number of items developing fully significant system will require a
large no. of digits which may not be manageable.
 Therefore, in Railways we have designed a 8 digit semi-significant coding system in which first 4 digits
signify some property of the material while other 4 digits are non- significant. This code No. is known as
Price List No. or PL NO.

 All the Railway materials have been classified in 76 `Major Groups' or 'Main Groups' or groups.
Each Major/main group (or groups) has been further classified into several sub- groups. Great
care has been taken to ensure that groups and sub-groups do not overlap and the numbers have
been allotted in a meaningful order and also they are unique.

2 Each PL No. is sub-divided into 4 parts as under; 90 35 058 3

Part A -- First Two Digits

Part B -- Third and fourth Digits

Part C-- Fifth, Sixth- and seventh-digit

Part D-- Last digit

Part `A' consists of two digits representing the main group of stores to which the item belongs. in the
present example main group is `90' which is for steel items.

Part `B' consists of two digits representing sub-group. Each group has been further divided into sub-
groups. Here `35' is the sub-group which is for various sizes of Mild Steel Flats. The sub-grouping for the
most of rolling stock groups is on the basis of major assemblies of which the item is a part.

Part `C' consists of 3 digits and is the serial number of the item within the sub group. No significance is
attached to this number. In the above example serial number is 58.

Part `D' consists of one digit which has a special significance with reference to computerization. This is
the check digit. This digit is unique to a given number and is intended to check the integrity of the code
number.

Method of verifying P.L. NO:

Wherever the computer encounters a code No. during processing, it calculates the check digit on the
basis of modulas 11 and checks if the calculated digit tallies with the check digit shown on the document
and punched. If the two do not tally, the voucher is rejected.

Method :Calculation method is given below.

CHECK DIGIT : DATA VALIDATION WHILE PROCESSING;

1. WRITE 2 TO 8 BELOW EACH DIGIT OF CODE FROM RIGHT TO LEFT EXCEPT CHECK DIGIT,
2. MULTIPLY THE DIGITS VERTICALLY &
3. ADD PRODUCTS OF MULTIPLICATION HORIZONTALLY,
4. DIVIDE THE SUM OF PRODUCTS BY 11,
5. THE REMAINDER OF DIVISION IS CHECK DIGIT (RIGHT MOST DIGIT IF YOU GET 2-Digit
REMAINDER)

Sample Check digit calculation:

2516104?

XXXXXXX

8 7 6 5 4 3 2 - 16 + 35 + 6 + 30 + 4 + 0 + 8 = 99

99/11 = 11*9 + 0 , i.e. Remainder = 0

Therefore, Check digit = 0

 MAIN GROUPS CODES

00-09 STEAM LOCO SPARES

10-19 DIESEL LOCO SPARES
20-29 ELECTRIC LOCO SPARES
30-39 CARRIAGE & WAGON SPARES
40-49 ELECTRICAL STORES
50-59 SIGNAL & TELE- COMMUNICATION STORES
60-69 PERMANENT WAY & ENGG. STORES
70-99 GENERAL STORES 98 SCRAP

Unification of P.L. NO: A Price List number may be either unified or non- unified. If a Price List number
for an item is unified, all the Railways and Production unit uses same number as PL code for this item.
This facilitates easy exchange of information between the Railways. Disposal of surplus stores and
centralized purchase become easier. In case of non- unified Price List numbers, all the Railways do not
use same code for the same item. Our attempt is always to have unified Price List numbers.
 Schedule 2

Washing Line
The washing line in Indian Railways is an essential facility used for maintaining the cleanliness and
hygiene of train coaches. It is a dedicated area where the train coaches are thoroughly cleaned using
water, detergent, and specialized cleaning equipment.

The washing line helps in removing dust, dirt, and other debris that accumulate on the exterior surfaces
of the train coaches during their journey. It also plays a crucial role in maintaining the visual appeal of
the trains and ensuring a pleasant travel experience for passengers.

The washing line in Indian Railways is equipped with modern facilities and machinery to efficiently clean
and wash multiple train coaches simultaneously. The process involves high-pressure water jets, brushes,
and scrubbing mechanisms to ensure a thorough cleaning of the coaches.

WORKS CARRIED IN WASHING LINE.

1) Cleaning & Washing
2) Break Testing by RTR [ Rack Test Rig]
3) Primary Maintenance
4) Secondary Maintenance
5) Inspection
6) Pantry Car Provisions
7) Watering
8) Loading of Linen
9) Maintenance of AC & electrical circuit of coaches

AUTOMATIC COACH WASHING PLANT –

INTRODUCTON TO AUTOMATIC COACH WASHING PLANT

The Automatic Coach Washing Plant is a multistage external cleaning system for coaches/trains, using
high pressure water jet, horizontal and vertical rotating nylon and cotton combination brushes. Konkan
Railway Corporation Limited can supply & install Automatic Coach Washing Plant on Turn-Key basis at
any Coaching Depot on Indian Railway. An Effluent Treatment and water softening plant can be provided
separately.

NEED FOR AUTOMATIC COACH WASHING PLANT

The Automatic Coach Washing Plant is able to achieve complete exterior cleaning of a rake of 24 coaches
in about 15-20 minutes time while being placed on the pit line, for primary/secondary maintenance.
Besides providing safe and reliable service to our esteemed passenger, it is also necessary for the
Railways to offer the convenience of neat and clean coaches.

ADVANTAGES
 Excellent external cleaning quality of full-length trains achieved within 15-20 minutes,
while being placed on the pit line for primary/secondary maintenance.
 The plant does away with the very labour-intensive activity of external cleaning of
Passenger trains on Indian Railways.
 Reduced requirement of water and consumables as compared to conventional cleaning
methods
 . Has minimal electrical energy, maintenance and manpower requirement for operation.
 Eco-friendly. Uses minimum quantity of water, soaps and disinfectants. Further, the
water used for the washing plant can be treated through ETP plant and recycled.

LAYOUT AND CONSTRUCTION –

The Automatic Coach Washing Plant can be installed at the entry point of the train examination pit at
coaching depots. This consists of 4 fabricated structures. Overall Length of the plant is 30M and width
5.26m across Railway Track, with additional space requirement beside the track of 4x5.5m & 2x2m for
Pump/Operating room and air reservoir. ETP if required will need additional space of 4x5.5m.

Control Room

 A control room is provided with underground tank of 20,000 litters and over head syntax tank of
5,000 litres for soap solution.
 Electrical / Electronic operating panel with electrical fittings, wiring etc. is provided in the control
room with PLC control system for automatic working of the entire plant. Manual option is also
provided.
  Three sets of pumps with spare pumps are provided in series with an arrangement to switch
over in case of break down

Stage # 1 - Prewash Unit

a. Pre-wash is the first operation in the washing sequence.

b. Pre-wash operation wets the coach walls and roof through low velocity water jets.
c. Pre-wash operation helps to loosen dust & dirt from the coach exterior

Stage # 2 - Soap solution spray and the First brush

a) Pressurised mixture of soap solution is sprayed on coach body and roof.

b) The soap solution is then brushed on coach walls and roof with help of four vertical i.e. two on
each side and one horizontal brush placed on the roof of the coach.
c) All brushes are driven by gear motors

Stage # 3 – Under-gear cleaning

a) Pressurised jets of water and disinfectant directed towards toilet discharge area clean the areas
beneath the toilets which are not otherwise accessible.
b) The jets also clean the under-gear portion of the trolleys.
c) Disinfectant spray prevents breeding of cockroaches.

Stage # 4 – Main wash

a) Total eight vertical brushes – four on either side – are used to wash vertical walls of the
coaches. One horizontal overhead brush is used to wash roof of the coaches.
b) All brushes are driven by motors.
c) This work-station thoroughly cleans areas such as, window shutters, destination boards
and reservation charts are also removed.
PRIMARY MAINTENANCE

 The trains for the primary maintenance are given at least 6 hrs at the washing line in addition to
secondary maintenance .
 Oil in hydraulic dash pots
 Wheel profiles are visually examined and gauged.
 Pest control treatment.
 Axel box is examined for grease, oozing out from rear cover.
 Break Blocks and pistons stroke checked and changed.

SECONDARY MAINTENANCE

1) The trains for the secondary maintenance are given at least 2 hrs on the washing line .
2) Linen & pantry car provisions.
3) Washing & Cleaning of coaches.
4) Maintenance of AC coaches.

BREAK TESTING IN WASHING LINE

1) Brake testing is carried by using RTR (RACK TEST RIG)

2) Rack testing rig is capable of testing full train (up to 24 coaches) at a time.
WORKING OF RAJDHANI EXPRESS: -
The Rajdhani Express is a series of passenger train services in India operated by Indian
Railways connecting the national capital New Delhi with the capitals or the largest cities of various
states. The word Rajdhani has been derived from the Sanskrit language, which means Capital in English.
This series of trains regularly gets the highest priority in the Indian Railways and is considered as its most
premium train.

Rajdhani express gets the highest priority on the Indian railway network. They are fully air-conditioned.
Passengers are served optional meals (food price included in the train fare) during the journey.
Depending on the duration and timings of the journey, these could include morning tea, breakfast,
lunch, high tea and dinner. All Rajdhani Express trains offer three classes of accommodation: AC First
Class (1A) with 2-berth and 4-berth coupès (with locking facility for privacy), AC 2-tier (2T) with open
bays (4 berths/bay + 2 berths on the other side of the aisle of each bay), provided with curtains for
privacy, and AC 3-tier (3T) with open bays (6 berths/bay + 2 berths on the other side of the aisle of each
bay) without curtains.
Currently there are 25 pairs of trains, connecting New Delhi to important cities across the country. These
trains have fewer stops than other express trains and halt only at prominent stations. Recently Dynamic
pricing has been introduced on all Rajdhani express trains.
 TRAIN HAVING LHB COACHES -
LHB (Link Hofmann Busch) coaches are a type of passenger railway coaches used India. They are
manufactured by the Integral Coach Factory (ICF) in Chennai and the Rail Coach Factory (RCF) in
Kapurthala. LHB coaches were introduced in the late 1990s as a replacement for the older ICF
coaches.

1) Anti-climbing features: LHB coaches are designed with anti-climbing feature, which help prevent
coaches from climbing over each other during accidents.
2) Improved suspension system: LHB coaches have a better suspension system.
3) Enhanced safety features: LHB coaches have improved safety features such as anti-telescopic and
anti-fire measurement.
4) Higher speed potential: LHB coaches are capable of higher speeds compared to the older ICF
coaches.
5) Air-conditioning and modern amenities: LHB coaches are equipped with air-conditioning and
modern amenities like bio-toilets, improved seating arrangements, and better onboard facilities.

MAINTENANCE SCHEDULES TO BE FOLLOWED IN COACHING DEPOTS

To maintain coaching stock in good condition, the following preventive maintenance schedules are
prescribed to be carried out in carriage depots on divisions where rake has been based for primary
maintenance.
The different schedules that are carried on the primarily maintained coaching stock are:
a) Trip Schedule - At the end of each trip by primary maintenance depot.
b) 'A' Schedule - 1 month ± 3 days (Monthly)
c) 'B' Schedule - 3 months ± 7 days (Quarterly)
d) 'IOH' Schedule - 9 months + 30 days
e months + 30 days (After 24 months for newly built
e) POH Schedule - 18 months (24 months for newly built)
42 Month (ATR/ARME)

AMOUNT OF AIR -

Authority-RB's L/no.83/M(N)/951/34dated25-05-1999

Air Brake Engine Rear Brake van

Mail/Exp/Pass. BP-5±0.1 kg/cm² BP-4.8-5.0 kg/cm²
FP=6±0.1 kg/cm² FB-5.8-6.0 kg/cm²

Goods BP-5±0.1 kg/cm² BP-4.8-5.0 kg/cm²

 Schedule 3

Linen Management For Indian Railways

Linen distribution –
linen distribution refers to the provision of bed linens, towels, and other essential items to passengers
traveling on long-distance or overnight trains. This service is primarily offered in countries where long
train journeys are common, such as in certain regions of Europe, Asia, and other parts of the world.

The process of linen distribution in railways typically involves the following steps:

Preparation: Before the train's departure, the train staff ensures that each berth or cabin is equipped
with clean and fresh bed linens, including bedsheets, blankets, and pillows, as well as towels for
passengers to use during their journey.

Linen Storage: The train is stocked with a sufficient supply of clean linen items. This linen is either stored
onboard in designated compartments or loaded onto the train at the starting station.

Distribution: As passengers board the train, the train staff may either provide the linen directly to each
passenger or place the linen items on the berths or in the cabins for passengers to pick up themselves.

Usage and Collection: Throughout the journey, passengers use the provided linen items for sleeping and
personal hygiene. For longer journeys, additional linen change and cleaning services may be offered,
depending on the train and class of service.

Laundering: After the journey or during scheduled maintenance stops, used linen items are collected by
the train staff. These items are then sent for laundering, and fresh, clean linen is restocked for the next
set of passengers.
The provision of linen in railways is a standard practice in many countries and is aimed at ensuring the
comfort and convenience of passengers during their travels. However, it's important to note that the
specific details of linen distribution can vary from one railway operator to another, and not all trains or
classes of service may offer this amenity.

As my knowledge is based on information up to September 2021, there may have been updates or
changes in railway services since then. For the latest and most accurate information on linen distribution
on railways, it's best to refer to the specific railway operator or their official website.

The washing and transportation of linen are essential processes in various industries, including
hospitality, healthcare, and railways. Proper cleaning and handling of linen are crucial to maintaining
hygiene, ensuring guest or patient comfort, and extending the lifespan of the linen items. Let's take a
closer look at these processes:

Washing of Linen:

1. Collection and Sorting: Used linen items are collected from their respective locations, such as
hotel rooms, hospital wards, or train cabins. Before washing, the linen is sorted based on factors
like fabric type, color, and level of soiling.
2. Pre-Treatment: Depending on the type of stains or soiling, some linen items may undergo pre-
treatment, where specific stain removers or cleaning agents are applied to remove tough stains
or odors.
3. Washing Machines: The sorted linen is loaded into industrial washing machines. These machines
are designed to handle large volumes of linen and are programmed for appropriate water
temperature, detergent usage, and washing duration, depending on the fabric type and level of
soiling.
4. Drying: After washing, the linen is transferred to commercial dryers, where they are dried at
controlled temperatures. Proper drying is essential to prevent mildew growth and maintain the
quality of the linen.
5. Folding and Ironing: Once dry, the linen is folded neatly and may undergo ironing to ensure a
crisp appearance. Linen used in the hospitality industry, such as bedsheets and tablecloths, often
undergoes ironing to create a polished presentation.
6. Quality Check: Before distribution, the clean linen undergoes a quality check to ensure it meets
the required standards of cleanliness and appearance.

Transportation of Linen:

 Packaging: The clean and folded linen is packed into bundles or bags, depending on the type and
quantity of linen items.
 Loading: The packaged linen is loaded onto transport vehicles such as trucks or vans for delivery
to the respective destinations. In some cases, for railways or large hotel chains, linen might be
transported in dedicated linen supply vehicles.
 Delivery: Linen is transported to various establishments, such as hotels, hospitals, or railways,
according to their linen distribution schedules and requirements.
 Inventory Management: Establishments that regularly receive linen deliveries maintain careful
inventory management to ensure an adequate supply of clean linen and timely restocking.

Schedule 4
 MACHINERY & PLANT
ELECTRIC AIR COMPRESSOR

Electric air compressors are devices that use electricity as a power source to generate compressed air.
They are commonly used in various applications and industries, including automotive, manufacturing,
construction, and home use.

Electric air compressors provide a convenient and efficient way to generate compressed air without the
need for gasoline or diesel fuel.

INNER PARTS OF ELECTRIC AIR COMPRESSOR

The following key features and benefits of electric air compressors.

1) Power source: - Electric air compressors are powered by electricity,either from a

standard electrical outlet or a dedicated power source.

2) Efficiency: - Electrical air compressors are known for their energy efficiency. The convert
electrical power into compressed air with high efficiency, resulting in lower operating
costs compared to gasoline or diesel-powered compressors.

3) Convenience: - Electrical air compressors are easy to use and maintain. They typically
require minimum setup, and you can start them by simply plugging them into a power
source.
They also produce less noise and vibration compared to their gasoline or disel
counterparts.

4) Clean and oil-free air: - Electric compressors often feature built- in filters and can provide
clean and oil – free compressed air.

5) Reduced emissions: - Electric air compressors do not produce exhaust emissions like
their gasoline or diesel counterparts.

DIESEL AIR COMPRESSSOR -

A diesel compressor, also known as a diesel-powered air compressor, is a type of air compressor that
utilizes a diesel engine as its power source. It operates by converting the energy, which drives the
compressor to generate compressed air.

Fig- Diesel Air Compressor

The following key features and advantages of diesel compressor: -

1) Portability: - Diesel compressors are typically designed to be portable and self-contained units.

2) High power and performance: - Diesel engines are known for their high torque and power
output, which translates into excellent performance for air compressor.
Diesel compressor can generate higher air pressures and flow rates compared to electric
compressors.

3) Higher efficiency: - Diesel compressor can be more cost-effective and efficient compared to
electric compressors due to their fuel efficiency and extended runtime.

 Inner parts of diesel air compressor shown in below figure

Electric Welding Transformer

Welding of rails is done mainly by three methods i.e Gas pressure welding, Flash Butt welding, Alumino-
thermic welding (Thermit welding)

The transformer, housed in a welding machine, is used to convert the higher-voltage input or, primary
power, from the wall plug and this is usually from 208 to 600 volts,with a low alternating current from 15
to 55 amps. This is transformed in the secondary power side to a lower voltage of up to 80 volts and a
range of welding currents up to 1000 amps AC or more, depending on the process and equi
 Schedule 5
Sick Line
 Introduction
o Working in the Sick Line of Indian Railways involves maintaining and repairing
railway rolling stock, including coaches and wagons.
o The Sick Line ensures safety, reliability, and efficiency in the railway network.
 Overview of the Sick Line
o The Sick Line is a designated workshop for coach and wagon maintenance and
repair.
o It plays a crucial role in keeping the rolling stock in optimal condition.
 Maintenance and Repair Activities
o Skilled technicians and engineers handle tasks like routine inspections, servicing,
minor repairs, major overhauls, and refurbishments.
o Their expertise ensures proper functioning and longevity of the rolling stock.
 Skill Requirements
o Working in the Sick Line requires specialized knowledge in mechanical,
electrical, and pneumatic systems.
o Continuous training is essential to stay updated with evolving technologies.
 Safety and Quality
o Safety protocols are strictly adhered to in the Sick Line to protect employees and
colleagues.
o Maintaining high-quality standards in repairs ensures reliable coaches and
wagons.
 Work Schedule
o The Sick Line operates 24/7 to meet demanding railway schedules.
o Employees work in shifts for continuous maintenance and repair services.
 Teamwork and Collaboration
o Efficient teamwork among technicians, engineers, and supervisors ensures
effective maintenance and repairs.
 Career Growth and Opportunities
o Skilled technicians and engineers have the potential for career advancement
within the railway department.
 Conclusion
o Working in the Sick Line is essential for maintaining the Indian Railways.
o Skilled personnel, safety measures, and teamwork ensure safe and reliable railway
operations.

ROLLING STOCK
Rolling stock refers to the vehicles that run on railway tracks, transporting passengers or goods, including
coaches, multiple units, freight wagons, and tank cars. It is a fundamental component of any railway
system.

ROLLING STOCK

LOCO COACHES

WAGGONS RAIL

ART(Accidental EMU AND

Relief Train)CAR DEMU AND
AND RAILBUS MEMU
 GAUGES OF
RAILWAY
TRACK

Narrow Gauge
Metre Gauge Broad Gauge
(0.762m or
(1m) (1.676m)
0.610m)
 LOCO/ENGINE

STREAM DIESEL ELECTRICAL

There are 3 types of loco in Indian railway –

1. Steam engine (Fairy Queen)

One of the world’s oldest working steam BG locomotive. The locomotive was built in the year 1855 by

M/s. Kitson Thompson and Hewitson Leeds U.K and can run up to 25 miles an hour. This locomotive is

also named in Guinness book world records since 1998 as world’s oldest working steam locomotive.

2. ELECTRIC ENGINE 3. DIESEL ENGINE (36 YRS)

 G – Goods  G – Goods

 P – Passenger  P – Passenger

 M – Mixed (goods and passenger)  M – Mixed (goods and passenger)

 S – Shunting (switching)  S – Shunting (switching)

 COACHES

LHB ICF HYBRID

ICF VS LHB -

 TIME

 COMFORT

 SAFETY

 MONEY

ICF

The design of the coach was developed by Integral Coach Factory, Perambur, Chennai, India in
collaboration with the Swiss Car & Elevator Manufacturing Co, Schlieren, Switzerland in the 1950s.

SPEED- 110-130 KMPH

BRAKING SYSTEM- DYNAMIC

SUSPENSION SYSTEM:
1. Coil Spring Suspension:

 ICF coaches typically use a coil spring suspension system.

 Coil springs are cylindrical helical springs made of steel or other materials with good elasticity.

2. Primary Suspension:

 The primary suspension of ICF coaches is responsible for supporting the weight of the coach and

passengers.

 It connects the bogies (wheelsets) to the coach body and provides vertical movement flexibility.

3. Secondary Suspension:

 The secondary suspension in ICF coaches helps further improve ride comfort.

 It consists of additional components between the bogie and the coach body to dampen

vibrations and ensure a smoother ride.

4. Dampers or Shock Absorbers:

 ICF coaches are equipped with dampers or shock absorbers to control the motion of the

suspension system.

 These devices help dissipate energy from vibrations and reduce the impact on passengers.

5. Wheelsets and Bogies:

 The wheelsets are connected to bogies, which are the undercarriage framework supporting the

coach.
  The bogies play a crucial role in distributing the weight evenly and allowing the coach to

negotiate curves and uneven tracks.

6. Ride Comfort:

 The combination of coil spring suspension, dampers, and well-designed bogies contributes to a

reasonably comfortable ride for passengers.

 While not as advanced as modern LHB coaches, ICF coaches still provide acceptable ride quality

on most railway lines.

 COIL SPRING

LHB

Linke Hofmann Busch (LHB) coach is a passenger coach of Indian Railways that is developed by Linke-

Hofmann-Busch of Germany and mostly produced by Rail Coach Factory in Kapurthala, India.

They have been used since 2000 on the 5 ft 6 in (1,676 mm) broad gauge network of Indian railways.

Initially, 24 air-conditioned coaches were imported from Germany for use in the Shatabdi Expresses,

after which the Rail Coach Factory started manufacturing after technology transfer.

IR declared that all ICF coaches will be replaced by LHB coaches to provide more safety and comfort. The

ICF Coach was flagged off making way for the LHB Coaches to be used for most of the new coaches

introduced in Indian Railways.

SPEED-160 KMPH-180 KMPH

BREAK SYSTEM- AIR

SUSPENSION SYSTEM

The suspension system of LHB (Linke Hofmann Busch) coaches is a significant improvement over the
older ICF coaches. LHB coaches are known for their superior ride quality and enhanced passenger
comfort. Here's an overview of the suspension system in LHB coaches:

1. Air Spring Suspension:

 LHB coaches use an air spring suspension system, which is one of the primary reasons for their
improved ride comfort.
 Air springs consist of rubber bellows filled with compressed air, providing better cushioning and
damping characteristics.

2. Primary Suspension:

 The primary suspension in LHB coaches supports the weight of the coach and passengers.
 Air springs are positioned between the bogies (wheelsets) and the coach body, providing a
smoother and more flexible movement.

3. Secondary Suspension:

 LHB coaches have a sophisticated secondary suspension system for further enhancing ride
comfort.
 The secondary suspension includes additional components, such as lateral dampers and yaw
dampers, to reduce vibrations and lateral movement.

4. Dampers or Shock Absorbers:

 Like ICF coaches, LHB coaches are equipped with dampers or shock absorbers to control the
motion of the suspension system.
 However, the combination of air spring suspension and dampers in LHB coaches offers
significantly better ride dampening.
5. Anti-Roll Bars:

 LHB coaches are equipped with anti-roll bars to minimize lateral swaying during curves, further
stabilizing the coach.

6. Wheelsets and Bogies:

 The wheelsets are connected to bogies, which are designed to optimize weight distribution and
stability.
 The bogies' design allows for smoother negotiation of curves and uneven tracks, contributing to
a more stable ride.

7. Improved Passenger Comfort:

 The air spring suspension system, combined with other advanced features, provides a quieter,
smoother, and more comfortable ride for passengers.
 The reduced vibration and swaying enhance the overall travel experience.

8. Lightweight Construction:

 LHB coaches are designed with lightweight materials, resulting in reduced overall weight, which
benefits energy efficiency and operational costs.
 NESTED SPRING

LHB coaches have gradually replaced ICF coaches on many trains in the Indian Railways due to their
superior features, including the advanced suspension system that significantly improves ride quality and
passenger comfort. The adoption of LHB coaches has become a standard practice for Indian Railways to
modernize its rolling stock and provide a better travel experience to passengers.

HYBRID

ICF(BOGI)+LHB (COACH)

A "hybrid coach" typically refers to a railway passenger coach that incorporates both electric and diesel
propulsion systems. These coaches are designed to operate on both electrified and non-electrified

railway tracks, offering flexibility and efficiency in train operations.

Here are the key features and benefits of hybrid coaches:

1. Dual Propulsion Systems:

 Hybrid coaches are equipped with both electric and diesel propulsion systems.
 They can draw power from overhead electric lines on electrified tracks and switch to diesel
power when operating on non-electrified sections.

2. Flexibility in Operation:

 Hybrid coaches can seamlessly transition between electric and diesel modes, making them
suitable for routes that have both electrified and non-electrified sections.
 This flexibility allows trains to operate on a wide range of railway lines without the need to
change locomotives or coaches at electrification boundaries.

3. Energy Efficiency:

 The electric propulsion system offers energy efficiency when operating on electrified tracks, as it
relies on power from the grid, reducing fuel consumption and emissions.
 The diesel propulsion system provides the ability to run on non-electrified routes where
electrification may not be available.

4. Reduced Environmental Impact:

 Hybrid coaches can contribute to reduced emissions and lower environmental impact compared
to fully diesel-powered trains.
 On electrified tracks, they can operate with lower carbon emissions, especially if the electricity
comes from renewable sources.

5. Cost Savings:

 Hybrid coaches can potentially lead to cost savings by utilizing cheaper diesel fuel on non-
electrified routes.
 They eliminate the need for additional locomotives or coaches for the transition between
electrified and non-electrified sections, streamlining operations.

It's important to note that hybrid coaches are still relatively new in the railway industry, and their

adoption may vary depending on the specific requirements of different railway networks.
DIFFERENCE ICF LHB

1.Length Body 21337 mm 23540 mm(Body to Body)

2.Length over CBC 22297 mm 24000 mm(cbc to cbc)

3.Width 3245 mm 3240 mm

4.Overall height from rail 4200 mm 4039 mm

level(patri)

5. Center pivoted distance 14783 mm 14900 mm

6. Wheel base 2896 mm 2560 mm

7. Bogie weight (trolly) 6.2 Tons 6.3 Tons

8. Wheel Dia 915 mm 915 mm

Condemn Dia 840 mm 855 mm

9. Coupling Screw CBC(Center Buffer

Coupling)

10. Breaking Clutch type Disc type

(110-130) km/h (160-180) km/h

11. Riding Index 3.2 - 3.75 2.8 - 2.75

12. Damper 4 9

13. Spring Coil Spring Nested Spring

14. Brake Cylinder or Breaking 2*2= 4(Roller 4*2=8(CTRB)

Bearing)
Suspension System - It consists Dampers and springs
Types of suspension system

 Primary Suspension - Main 4 corner springs (coil) dampers

 Secondary Suspension- B/W COACH AND BOGIE

Generation In Indian Railway -

1. Self Generation- Self Generation (Alternator)+Battery(ICF)

2. End Generation- Generation both end sides(LHB)

3. HOG (Head on generation)- Loco pentograph

4. Mid on Generation- Diesel engine at mid (MEMU)

Wheels and Wheel Defects

Railway Wheels • Railway wheel is assembly of two wheels fixed to the axle by interference fit and they
rotate along with the axle, without any independent relative movement as in the case of other
automobile wheels.

• These wheels are provided with flange towards the inner side, which guide the wheels to travel on the
rails and does not allow it to fall down from the rails.

Material of Wheel

Steel made by Electric or Basic Oxygen process

• Steel shall be of killed quality for forged steel
• The max hydrogen content shall not exceed 3 ppm
• The max nitrogen content shall not exceed 0.007%
Wheel defects Measurable wheel defects arising due to normal wear & tear during service are of two
types

1. Flange Defects

• Thin flange
• Deep flange
• Sharp flange

2. Face Defects

• Less radius at root of flange

• Hollow tyre
• Thin tyre
• Flat tyre

TOILET SYSTEM
Types of Toilet System

 ODS- Open Discharge System

 CDTS- Control Discharge Toilet System
 Bio Toilet System - Its contains anaerobic bacteria which comes from the glaciers of antarctica
which eats waste and converts into methane and water.

CODING OF COACHES IN INDIAN RAILWAY -

1. LWLRRM

2. LWCBAC L- LHB

3. LWACCN W- Vestibule

4. LWACCW L- Luggage

5. LWFAC AC-Air condition

6. LWSCN F-1ST AC

S-Sleeper

RRM - Power

CN- 2nd tier

CW-3rd tier
 Schedule 6
Train Duty

TRAIN EXAMINATION (Coaching)

TYPES OF EXAMINATION

 Rolling-in examination
 Rolling-out examination
 Originating examination
 Terminating examination
 En-route/Passenger-through examination
 Safe-to-run examination
 Trip examination

ROLLING-IN-EXAMINATION

Occasion-

 Rolling in examination is conducted on the passing through and terminating train while it enters
to the platform or yard.

Preparations -

➤ C&W staff take their position at the both sides of reception end of the platform 5 to 10 minutes in
advance on arrival of the train

➤ Ensure the last rolling stock of the train rolls before them and stop. During this examination Staff
should watch out vigilantly for –

 Loose parts
 Hanging parts
 Broken under gear parts
 Unusual sound of flat tyres
 Hot axles
 Broken springs
 Defective brake gear.

Advantages -

 Some of the under-gear defects can be easily detected only when the train is in motion
 ➤ Platform side of a passenger train, at a passing through station, cannot be easily examined
due to want of time and movement of passengers
  In rolling-in examination this could be examined and can be noted and replacement done within
available time.

Facilities required

 Both sides of the place of rolling-in examination should have unobstructed view of under-gear
 ➤ Speed of the train shall not be more than 30 kmph
 Should have adequate space for fixing the lighting arrangement on both side of the track.

ROLLING-OUT EXAMINATION
Occasion -

 Rolling-out is conducted on all the passing through trains after departure from platform or yard.

Reasons -

 Rolling-out examination is carried out specially to ensure that brake cylinder piston and brake
gear components are in fully released condition specially after :-
 Attachment of train loco at starting station
 Change of loco en-route
 Detachment/attachment of wagon/coach/banker en-route.

Rolling in Rolling out items in ICF Coaches: -

 Hanging Parts: - Equalizing stay rod, J-Bracket, Truss bar, hanger, Axle box cover.
 Hox axle: - Smoke from axle box bearing.
 Broken part: Spring, Truss bar hanger etc.
 Air pressure leakage: - Hissing Sound from air brake pipes.
 Buffer height variation: - No Axle box clearance, excessive Bolster clearance,
Body resting on trolly (Thumping sound).
 Deflected air spring: -
 Brake binding: - Sparking from wheels.
 Wheel skidding: - Unusual sound.
 Securing arrangements of tanks: -
 Bending of footboard: - bend/damage.
Rolling in Rolling Out items in LHB Coaches: -

1. Hanging parts: - Securing arrangement Anti -roll bar, Axle box face plate, WSP Cable, Link, Water
pipe and Battery box etc.
2. Hot axle: - Smell/smoke from axle box.
3. Broken parts: - primary & secondary springs, Deflated air spring etc.
4. Wheel skidding: - Unusual sound from wheel tread.
5. Securing arrangement of all tanks: - CDTS tanks, Bio-toilet tanks, under-slung tank, AR tank &
Brake Control module including footboard CBC uncoupling device.
6. Air pressure leakage: - Hissing sound from air brake pipes.
7. Deflated Air Spring: - Uneven Air Spring.
8. Brake binding: - Brake indicator applied.
9. I.V Coupler sagging: - sagging of I.V coupler.
10. Whistling sound: -
11. From brake pad.
12. Brake disc
13. Bearing front & back.
14. Earthing box.

Brake power certificate: - It is also known as a brake force certificate or brake test certificate. Brake
power certificate is a document issued by Carriage & Wagon department of India Railway for every
moving train (Coaching trains or Wagons). Brake power Certificate includes several important
information which is useful for the movement of the train.

Axle box feeling: - The axle boxes having grease oozing, burning smell, missing/loose grease seals and
burnt EM pads are the indicators of potential hot box cases. The above instructions should be displayed
at the axle box feeling points for the guidance of the technicians.
 Safe To Run Examination
The terms “safe to run examination” is not a standard or widely used phrase in the railway industry. It
seems to refer to an examination or inspection conducted to determine if a train or rolling stock is in a
safe condition to operate.

In railway operations, safety is of paramount importance, and trains must undergo various inspections
and examinations before they are deemed safe to run. These examinations typically involve a
comprehensive assessment of the train’s mechanical, electrical, and operational components.

Mechanical systems: - The train’s mechanical components, including braking systems, axles, couplers,
and suspension, are thoroughly inspected to ensure they are in good condition and functioning properly.

Electrical systems: - The electrical systems on the train, such as lighting, Signalling, control systems, and
communication equipment, are checked to ensure they are operational and meet safety Standards.

Safety features: - The presence and functionality of safety features such as emergency exits are verified.

BY – MD DILSHAD ALAM

THE END

THANK YOU….!!