Presented By:-

ANKUR SINGH
B.Tech- 3rd year
Roll No.:-0921540009
Contents
 Introduction to IR
 Introduction to Matunga Workshop
 Shops visited:
 Trolley Repair Shop
 Machine Shop
 Wheel Shop
 LUF
 Inspection
Introduction to IR
 Indian Railways abbreviated as IR is the central government-owned railway
company of India, which owns and operates most of the country's rail
transport.

 Railways were first introduced to India in 1853.

 Indian Railways has more than 64,215 km(39,901 mi) of track and 7,083
stations. It has the world's fourth largest railway network after those of
United States, Russia and China.

 As of 31 March 2011, 21,014 km of the total 64,215 km route length is

electrified.Since 1960, almost all electrified sections on IR use
25,000 V AC traction through overhead catenary delivery. A major
exception is the entire Mumbai section, which uses 1,500 V DC and is
currently undergoing change to the 25,000 V AC system.
Matunga Workshop
 The Carriage Workshop, Matunga was set up in 1915 to repair.
 The workshop carries out Periodical Overhauling (POH) of all type of
coaches including EMU Coaches of the Mumbai suburban section of
Central Railway.
 Matunga workshop is being certified as ISO 9001:2000 for Quality
Management System by Bureau of Indian Standard through audits of
documents and work practices since July 2001.
 The workshop undertakes following major activities:

ACTIVITIES TARGET

POH of Mail/Express Coach & POH of 147 coaches per month

Passengers Coach including 28 AC Coaches
Heavy Corrosion Repair 14 per month

POH of EMU Coach 60 coaches

TOTAL CAPACITY 243 Coaches per month

TROLLEY REPAIR SHOP
 This section is divided in two subdivisions:
 EMU trolley repair section
 Main line trolley repair section

 In EMU trolley repair section.

 Coach trolley.
 Motor Trailer coach trolley

 In main line trolley repair section

 13 ton trolley(Non-AC coaches)
 16 ton trolley(AC coaches)
DASHPOT ASSEMBLY

The lower spring seat plays the role of a

cylinder in the dashpot arrangement and is
filled with oil. In the dashpot arrangement,
the top portion is called the axle box guide.
The axle box guide is welded to the bogie
frame. The axle box guide works as a piston
in the Lower spring seat filled with oil. This
helps in damping the vibrations caused
during running train operation.
MACHINE SHOP
 GENERAL MACHINE SECTION:-

 Drilling machine
 Radial drilling machine
 Vertical drilling machine
 Gang drilling machine
 Shaper machine
 Planer machine
 Milling machine
 SHOCK ABSORBER
 There are mainly 4 manufacturers of shock absorber in
India.
 Escort 900kg/600kg capacity
 Gabriel 900kg/600kg capacity
 Knorr 900kg/600kg capacity
 India auto ltd. 900kg/600kg capacity

Shock absorbers serve the purpose of

limiting excessive suspension
movement, their intended sole purpose
is to dampen spring oscillations.
AIR SUSPENSION SYSTEM

The weight of the

car body (half of
it, since the other
half is carried by
the other bogie)
rests on the air
bag.
 Compressed air is fed into the air bag through a levelling
valve attached to the underside of the car body.
 The valve is operated by a lever attached to one end of the
link, whose other end is fixed to the bogie frame.
 Any vertical movement between the car body and the bogie
is detected by the lever which adjusts the levelling valve
accordingly.
 When the load on the car is changed at a station by
passengers boarding and alighting, the weight of the body
changes and the levelling valve adjusts the air pressure in
the air bags to match.
 The effect is that the car body maintains almost a constant
height from rail level, regardless of load.
 If the car load is reduced, the leveling valve will allow
excess air pressure to escape.
WHEEL SHOP
 Main parts of a wheel set:
 Axle
 Solid disc
 Axle box
 Roller bearing

 AXLE TYPES:

 13T- Dia 145 mm for sleeper coach

 16T- Dia 152 mm for AC coach
 130 mm Dia for main line coach
 140 m Dia for Motor coach and HCC coaches.
 Wheel shop is sub-divided into:

 Wheel repair Shop

 Wheel inspection Shop
 Wheel assembly
 Roller bearing

MAIN ACTIVITIES:

•Normal repair
•Re- Discing of wheel
•Re-Axeling of wheel
Roller bearing
 Spherical bearings are employed in the railways to
support the axles because
Spherical roller bearing has maximum load carrying
capacity.

 ZYGLO TEST:

 Dip the bearing in Fluorescent Penitrant Dilephor(for half

an hr).
 Remove it, spray dilephor powder on it.
 Check the bearing in ultra violet lamp for the smallest
crack in it.
 Types of Bearing

type Radial clearance No. of rollers

SKF 0.105-0.296 30

FAG 0.080-0.185 28

NBC 0.080-0.190 28
LUF
 The coaches which are entitled for periodical
overhauling(P.O.H) are made to halt at Dadar yard
from where 7 to 8 coaches are taken to Matunga
workshop daily.Once the coach enters the
workshop it is brought to the lifting and under
frame section where entire coach is lifted with the
help of 2 cranes having the capacity of 25 tones
each.Once the coach is lifted the trolley is sent to
the trolley repair shop.An inspection team is
appointed to inspect the amount of corrosion
occurred on the entire coach and then if any
corrosion repair work is required then it is sent to
the heavy corrosion repair shop.
INSPECTION DEPARTMENT
 In Railway Workshop every part of the Bogie & the Coach is
inspected for its correctness by Inspection Department.
 There are various Inspection Departments:-

 EMU Inspection:-
In this department under frame visual inspection of EMU
trains are carried out for its corrosion or cracks at welding
joints of parts like centre pivot, side bearers, head stock,
trough floor.
 Main Line Inspection:-
In the department under frame visual inspection of main
line coaches are carried out for its corrosion or cracks at
welding joints of parts like centre pivot, side bearers,
headstock, trough floor, sole bars.
 Carpentry Inspection:-
Here in this department interiors of coaches are
checked.

Wheel Inspection:-
Checking of profile, diameter and length.
Ultrasonic test
Hammer test