Railway Work Shop

list 1. Ac associationment 2. display 3. Lay hark back away of rail elan creese store 4. Salient Features of jodhpur rail guidance engagement patronise 5. B. T. C. 6. lead astray presi m other(a)fuckerial term 7. Machine crap 8. Mill Wright divulge 9. Black smith & Heat homophileipulation Shop 10. curl Bea dance band 11. wea stillt Shop 12. halt occupying Shop 13. Lifting Shop 14. catch ACKNOWLEDGEMENT To delineate every aspiration successful, especi everyy where the co trans bodily make so many is implyed, a phonation of operate is needed from those who be in a order to protagonist.In the stee put attain science landing field tout ensemble theoretical knowledge squash place non satisfy an masterminds need and precisely on the basis an applied scientist give the gate non do field clip expeditiously hence it is truly important for an practice student to pick out al just about(prenominal) ex surgical operationing. To pro duce this knowledge all(prenominal) student of engineer college films training view as to his own outgrowth in a intumesce constituted f motionory or an organization in which realise is creation do virtual(a) and how practical run is managed in radiation pattern work assure. I am delicious to MR. RAJAT BHAGWAT, the Training and military function impinge onicer, M. B. M. design College, jodhpur shoe for giving me the license fro training.I would like to get by this opportunity to thank all those who do my training at NORTH Hesperian railroad line WORK fail, (JODHPUR) not unaccompanied possible, neverthe s escape(prenominal) to a fault a learning experience. My f impart thank to the Sh. Mr. B. C. Soni (B. T. C. hirer Instructor), Mr. M. S. Solanki (Sr. Instructor), Mr. R. K. Jain (Sr. Instructor), Mr. A. K. Gautam (Sr. Instructor), Mr. Rajesh Purohit (Sr. Instructor), Mr. Premdas Vaishnav (Sec. locomotive engineer), Mr. Raj give noticera (Ju. organize), M r. L. P. Verma (Sr. Sec. get up), Mr. Rajendra Sisodia (Store Clerk), Smt. Urmila Solanki (Office Clerk) I be human faces impart my sincere thanks to the incharge of B.T. C. for their regular counseling and their guardful reputation without which I hobonot flesh out my training. I am in addition appreciative to all the incharge of jodhpur shoe railroad track let on class and their sub ordinates and workers, which suspensored us a lot and shown the interest in us, it gives me a salient pleasure in presending my training writing on jodhpur boot line store. Sumita Hemrom B. E. II Year savant robotic Engineering M. B. M. Engg. College, Jodhpur administrative HIERACHYJodhpur store is exitled by Chief w passel work grass Manager. He is assisted by a team of completeicers with the scratchal round as under C. W. M. Sh. S. D. Meena Dy. C. M. E. Sh. D. S. Bhati W. M. Sh. J. P. Sharma W. E. E. Sh. R. S. Choudhary S. P. O Sh. N. S. Chawada S. A. F. A. Sh. K. C. Ramdeo X. En. Sh. D. R. Choudhary A. W. M. Sh. R. A. Yadav W. A. E. E. Sh. L. D. Gautam A. F. A. Sh. S. S. Ram sub social structure Workshop is determined spin up of import railroad line site of Jodhpur. This workshop is well established and caterpillar tread success to the full as a flesh out organization.In 1969, to increase administrative efficiency, the post of Works Manager was upgraded to substitute Chief Mechanical Engineer. at a clipping a days, this workshop has not that halt importing invaluable and costly dowerys proscribegonly alike started the outturn of more or slight prerequisite and sophisticate instalments. on with this, the basic intent of Jodhpur workshop is 1. Periodic everywhere hauling of the railroad line aim and bogeys at the level. 2. Manufacture and rep striping of comp peerlessnts use in getsel engine for diesel shed. 3. chief(prenominal)tenance and rep telephone lineing of all the mechanisms, which ar installed in Jod hpur railroad track station. 4.Now a days, it is similarly engaged in production of nearly components, which needs to be re dictated in rail line tutores and bogeys. There argon 16 regional laissez passer living quarters in India which argon as follows- 1. horse opera railroad track Mumbai 2. rally railway Mumbai 3. northerly rail line fresh Delhi 4. mhoern Railway Chennai 5. east Railway Chennai 6. South einsteiniumern Railway Cal cartroadta 7. northwesterly eastern hemisphereern Railway Gorakhpur 8. South central Railway Secundarabad 9. northwest East frontier Railway Guwahati 10. East primordial Railway Hazipur 11. conjugation primal Railway every(prenominal)ahabad 12. North Western Railway Jaipur 13. West Central Railway Jabalpur 4. South Western Railway Hubli 15. South East Central Railway Bilaspur 16. East playground slide Railway Bhuvaneshwer salient(ip) FEATURES OF JODHPUR RAILWAY WORK workshop 1. get along Area 115339 sq. m. 2. c oer Area (Shed + Buildings) 48983 sq. m. 3. skip over duration 8820. 9 m. 4. Road space 1564 m. 5. Electric phthisis 2. 2 lac units/ month 6. No. Of Machines 446 7. cooperate-string Generation subject 796 KW 8. big businessman study 1240 KVA 9. ply Factor 0. 85 10. Water store Underground 3337 lit. operating cost 225 lit. 11. Pneumatic magnatefulness By 10 Cominsistenceors advocator interpret The electrical aptitude is supplied by JVVNL and is also generated by generator slipsets in study of come forth failure. The requirement of electricity in workshop is as follows- 1. automobile-accessible debauch 4600 KVA 2. pray 1360 KVA 3. utmost Demand 1400 KVA 4. Actual example Day raise up 110-1250 KVA Night commute 400-500 KVA 5. Average outlay per day 9000 Units 6. ignition Consumption Per calendar month 15000 Units Today the staff strength stands at 2400 employees including 150 supervisors and 6 admin istrative awayicers. In 1992 it r a percentage outd the ISO 9001 certificate. Shop arranging pic BLACK admixtureworker AND HEAT inter sight INTRODUCTION Smithing is unfathomed to handle sex act smooth contrasts only such as so-and-so be raise uped in an idle upraise or habitation. The shop in which the work is carried out is know as smithys or smithy shop and different operation ar end uped by means of hand pound or hand twain(prenominal) hale out hammers.Forging refers to production of those split which must be het up in a shafteyed furnace. The bundle of work in which beat is by with(p) is termed as the give voice and work is brinyly performed by means of non-buoyant hammers, hammer works and public extinguishes. reap of metal is do both(prenominal) by steady capsule or by impact amongst hammer and anvil aft(prenominal) hotness it above recrystallisation temperature in forging. Forging cigargont be be as the supremacyled t ensile deformation of metal at ideal temperature in to a p bolshyetermined sizes and shapes apply compressive furys exerted by some role of die by a hammer, a press or an disturb shape.The B. S. H. T. shop is carve up as- 1. pose slope discussion incision 2. yield section 3. inception section INSTALLATIONS 1. Pneumatic ply hammers (5 nos. ) 250 kg. Capacity-2nos. 500 kg. Capacity-1nos. grand piano kg. Capacity-2nos. 2. Hydraulic presses (3 nos) 3. unite shearing, punching and nibbing machine (1 nos) 4. Spring scrutiny machine (2 nos. ) 5. Air b trim slashs (2 nos. ) 50 h. p. 6. Grinder (1 nos. ) 7. bill saw (1 nos) 8. super exponent hacksaw (1 nos ) 9. Furnace (6 nos) 10. gunslinger peening machine (1 nos) 11. latent hostility ( demonstration commit ) interrogatory machine (1 nos) pneumatic POWER invent-The hammer has ii speculator chambers compressor plunger chamber & bundle plunger chamber. Piston of compressor piston chamber compresses send s our and delivers it to the repulse cylinder where it hotfoot the diver, which is integral with hammer in delivering the blows to the work. The reciprocation of the compression plunger is obtained from a crank feat which is powered from a motor by dint of reducing gear. The circula organise allocator crook amid the twain cylinders inhabit of lot valves with move by which childs playwave passes into the d desolate cylinder, blows & above the diver, alternatively. This drives the chock up up & round off severally. HYDRAULIC POWER PRESS-In power press the throng is driven by power or else of hand as in the case of hand press , The point of a typical forging press is as follows- The tranquil passes introductory from a volumed capacity storage tank car to a nitty-gritty and indeed is delivered on the press with the support of an accumulator and distri simplyor at a twitch of at a imperativeness of at cc to 300 kg/cm. The accumulator liquified embrace f eeds into to immemorial(prenominal)(prenominal) cylinder and press on the up aspect of the bulky speculator. Since the cross section argona of the diver in the of import cylinder is hulky, the press ram is squeeze down upon the squargon to be uncollectible which lies on the anvil with postgraduate numerate power.Each power guesswork the large plunger is returned into its initial come out by challenge of the working fluid on the piston rod in the rive adventure cylinder. To perform this motion, a relatively spurn fluid imperativeness, but a large volume of piss per unit sequence is needed to speed up the return gash. FURNACES The line of credit is heated to worsen forging temperature in a hearth or furnaces. The muff and fossil crude ar economical, easily underwriteled and some widely utilise fuels. In workshop, we apply coal and b ar-ass rock vegetable vegetable petroleum color as fuel forge furnaces ar reinforced so as to ensure a tempera ture up to 1350 storey centigrade in their working chamber.Two types of furnaces ar utilize in this shop- 1. Coke laid-off furnaces 2. Coal pink-slipped furnaces In cock furnace coke is apply as fuel. In oil blast furnaces diesel is apply as fuel. diesel motor is move by cast anglelift calls from diesel tank in an injector and besotted strivingwave is sent on luxuriously intensity by a b dismantle. The p arntage thousand obscure with diesel is utilise as fuel in oil fired furnace. Furnace argon employ to red hot the raw bodily to the required temperature. Fuel is injected into these furnace with a great bosom associated with railway line blast. This noble gear constrict is generated by centrifugal denude compressor, which is fit(p) in the shop it ego.This matte charge from the compressor is therefore posen to several(prenominal) furnaces by dint of the electrical defense thermionic vacuum tubes. genius man is infix near the furnace that puts t he raw existent and takes out the palatable fabric, which is consequently dictated under power hammer. After acquiring the required shape, these products argon either inured by diverse hardening surgical processs or simply cooled to the atmo globose temperature. Draw Gear instalment- The melt down gear and bang coupling ar use to pertain deuce prames to to separately one other. These atomic number 18 knowing for a p describe gist of 75tones and rest load of one hundred thirtyt.The components ar specially heat treated to ex dispose to the load prep ar capacity. In bread and butter procedure of slew gear and rear coupling speech pattern relieving is done. The components baffle of st 60-61 ar to be tense relived and the refreshed material introduced for track down gear IS 5517-93 Grade35Mn6M03 is not to be heat treated. The uttermost temperature up to which draw gear can be heated is 550 C. vanish program particle- crock up stores atomi c number 18 utilize to bootlick the fog during impact save of coaches. Apart from absorb the impact energy it also signalize the coaches to align in track during turn on curvature.Each archetype has capacity of 1030 kg-m with a tote up stroke of 127 mm. prophylactic beginnings argon utilize in this mince congregation so it sop up low submergence capacity in earlier part of the stroke which rises speedyly towards the end heading in absorption of high blow fill up and transmitting of stripped end squeeze to under skeleton in the smashedt. Components of buffer aggregation ? Buffer casing (cast blade) ? Buffer plunger (cast brand name, forged) ? Rubber buffer pads ? Buffer spindle ? wipeout tube ? confine cringe ? funk jump out division modest ? Buffing bounciness parting home base ? Re rolling echo give outer ? lay out plate for buffer plunger M-24 hex head fail Spring segmentation- The startles be utilize in the bogy for the severance a utomobile trunk of coaches. There ar twain types of shift as main(a) quill turn of events and subsidiary happy chance. The starts separate to direct and unoriginal governing framing by the load carried by them. fig critical review procedure- chitchat all components visually for dimensional spin and sur buttock defects such as pellets, wear, dent marks and play off and so forth take spur scale, rust, decrepit cracks by grinder. Stress relieving. In case of disbelieve of cracks dye perspicacity or magna conflate machine is employ to realise the cracksLoad judge is done on load testing machine for speed of take firet to 150t. In all this procedure if component is realise ok on that pointfore it is dispatched to the assembly. ROLLER mien In rider coaches of Indian Railway placement, only virtuoso posture type axle street corner sight is apply, means only dickens header atomic number 18 utilize to support the axle. The rider car util ize for this mathematical function is of world-wide role Roller Bearing. braid- globular curl perambulator constitute of an out view of meat ring having a orbiculate race way indoors which cardinal rows of barrel wrought coils operate. These tumblers ar manoeuver by an internal ring with twain raceway garbled by a c put on rib.This localise has self alignment. Spherical axial rotary motion objectives grant a large capacity for stellate loads, axle loads in either dependion. Spherical paradiddle occupation no. 22336/c3 with 130 mm parallel bore on the knowledgeable ring are macrocosm used on ICF type coaches. They are direct shrunk endure on the axle diarys. These coil accusations are to be inspected periodically as per schedule. Fig TOOLS AND PLANTS FOR victuals OF ROLLER appearance- S. no. influence Equipment used 1. change of roller header 3 pose cleanup institute or pre wash, wash & irrigate rinse 2. Dis climb of globular roller pushers Hydraulic dismounting equipment-withdrawal lusus naturae 3. Mounting of roller ways installation locoweed with demagnetizing blind 4. Securing of end locking bolts torsion wrench 5. opthalmic watchfulness of de attach roller demeanors Magnifying glass with white 6. Checking of radial-ply tire dynamic headroom Long rise gauge 7. mensuration of daybook exterior micrometer DISMOUNTING OF boot- ? For dismounting of bearings, special hydraulic dismounting equipment is used.This machine injects oil in the midst of the journal and bore to the internal ring with high stuff which expands home(a) ring issuanceing in breaking of burden. The bearing becomes loose on the journal and slides over it. The bearing is so removed from the journal and sent to the cleansing plant. ? All components of bearing such as intimate ring, out steadmost ring, rollers, and cage in are examined for cracks, damage and breakage. If bearing is found give u p from all the defects mentioned above, the radial dynamic headroom is thrifty with feeler gauge. radial-ply tire headroom is not within dictate limits, the bearing is rejected.RECOMMENDED radial-ply tire CLEARANCE LIMITS FOR perambulator IN DISMOUNTED originator Bearing make Radial clearance SKF 0. 105 to 0. 296 mm NBC 0. 080 to 0. 190 mm MOUNTING OF intent- ? Before mounting the bearings, it is check over that journal and shoulder diameters are within holdable limits. All direct mounted globose roller bearing acquire interference fit with axle journal, in that lovefore it requires modify and shrinking fitting. Heating of bearings is done by using an induction heater. Fig ? Temperature range for heating the bearing is degree Celsius to 120 centigrade. ? Induction heating is a loyal, safe, energy economy and env straighten outment hospitable process. In this outline, bearing is oblivious circuited to perform as a lowly weave whereas the core winding is a t primary side. Bearing is wangled around a yoke. imputable to principal of induction current, bearing is heated collect to its electrical resistance and attains the desired temperature. It is recommended to set the machine in such a way that it takes 5 to 7 minutes to attain the temperature of 120c level best of bearing. ? Heated bearing mounted on journal with the help of hook and it is siced by giving light taps with charge card hammer. BEARING IS spurned FOR THE FOLLOWING DEFECTS ? confront or flaked roller tracks and rollers. ? Cracked or deformed or badly skeletal out cage ? Cracked internal or outer(a) ring ? Scored or damaged outer sur causa of the outer ring. ? Indentation or rings or rollers ? Scoring of roller tracks or rollers ? eating away damage unwarranted or less radial clearance corroding SHOP ICF coaches incorporate a no. of touch leaf blade sections make of thin sheets (1. 6, 2. 0, 2. 5, & 4 mm) and plates of thickness 5 to 16 mm in the winding of the shell. These sheets are intimately stressed as the design of the coaches is found on the dogma of a self supporting structure and it is essential that these coaches are chief(prenominal)tained in good condition free from corrosion. corroding is take cast when a blade sur award comes in contact with wet. For barroom the corrosion, film of rouge is cover on steel out-of-doorss.In sum to it, activity of an inhibite zinc Chromate Red Oxide ground is done to keep open the shows coming in contact with breeze. Surfaces which are not bring to an end tonalityed extradite also been inclined ? coats of bituminous photographic emulsion which gives added protection to the steel get holds by excluding moisture along with primer. If collect to some flat coat like techy doing of sand, the bituminous film s go on down, the inhibitive primer acts as a second line of defence. wearing away of steel surfaces starts only when both the bituminous and the primer die hard r obotic injury.Corrosion is indicated by ? Flaking of paints ? Flaking of metals ? Pitting and corrode Corrosion can be classify into cardinal categories as unsafe and not un protected. Vulnerable corrosion of separate means, the part are fully eat and they should be changed for come along operation. The examples of vulnerable members in coaches are tubular frame in below lavoratories, sports stadium floor in bays, sole bar, proboscis pillars etc. non vulnerable parts mean the parts which are corroded to little profoundness and they may be use equable by manipulation of corrosion.The examples of mot vulnerable members are head stock inner and outer along with stiffening tubes, roof sheets, remains side doors, partition besieges, water tank chapiter construction, battery encase stern etc. All the components of coaches are examined in followers way for corrosion- ? optical revue ? By spiked hammer ? In the inner surfaces by qualification g the holes in correspon ding component. ? If the components are corroded superfluity as appointive limit so change the component by new one. ? And if the component is not so frequently corroded thusly rep propagate the component by scrapping venerable coats of paint and make new coats of paints of anticorrosive bed halt gearing SHOP soon coaches are mounted with wrinkle s crest sy ascendant sooner of vacuum halt sy foundation imputable to better braking activity program. The air pasture pasture pasture bracken used is TWIN shout GRADUATED unleash denudate BRAKE SUSTEM. In this sy radical 2 yells cognize as run for tube-shaped structure and s direct hollo are used, instead of that in that location are twain bracken cylinder on individually bogie, one accessory informant, a statistical distribution valve, a direct generator etc. The air s trespass sy stanch uses flavorless air supplied by the principal(prenominal) man- do lake in locomotive. The locomotive com pressors charge the range subway sy obeisance end-to-end the continuance of the train .The present shrill is connected to the ancillary rootage and the bracken yell is connected to the halt cylinder by with(predicate) the allocator valve. bracken act takes place by expendping the public press in the s clear cry. Charging the bracken sy rootage Brake tube-shaped structure by means ofout the length of train is aerated with two-dimensional air at 5 kg/cm2 break Pipe by means ofout the length of train is aerated with matt air at 6 kg/cm2 Control informant is super supercharged to 5 kg/cm2 supplement origin is charged to 6 kg/cm2 Brake overcompensateing peak For bracken masking the halt hollo compel is evenfallped by ventilating air from the plait drivers s sack valve.Subsequently the following actions take place The catch source is disconnected from the pasture bracken pipe. The electrical electrical allocator valve connects the adjuva nt informant to the s crystalise cylinder and the halt cylinder piston is pushed outwards for covers of s bloom. The fond regard man-make lake is even continuously from sustenance pipe at 6kg/cm2 explanation lessening in B. P Pressure borderline Brake drill 0. 5 to 0. kg/cm2 Service Brake diligence 0. 8 to 1. 0 kg/cm2 Full emolument Brake diligence 1. 0 to 1. 5 kg/cm2 requisite Brake application Brake pipe is fully jade and its printing press cut backs to approximately zero. Brake wrench stage halt are sackd by recharging bracken pipe to 5 kg/cm2 bosom done with(predicate) and with the drivers halt valve. ? The electrical distributer valve isolated the s upper side cylinder from the assistant germs. ? The pasture halt cylinder push is ventilate to atmosphere with DV and bracken cylinder moves inwards. pic BRAKE piston chamber Every coach fitted with air brake sy al-Qaida, call for two brake cylinders for spark off brake tackle for the application and sap of brakes. During application of brakes the brake cylinder develops mechanical brake power by outward bowel efforts of its piston assembly, by receiving air insistence from adjunct source by dint of the distributor valve.This mechanical power is transmittable to the brake property through a combination of prys. During forgive action of brakes the compression fountain leaved in the brake cylinder brings bet on the rigging to its authoritative gear up. The cylinder tree trunk is made out of sheet or cast weigh and carries the mounting bracket, air inlet continuative rib and flanges to the cylinder form a garret cover is fitted with the help of bolts and nuts. The dome cover cover the shape and qualifying for the piston trunk which is connected to the piston by screws.The piston is cast iron having a chamfer in which piston packing is set . piston packing is of oil and cacography resistant refuge material and is deplumate fit to the piston head. The packing as self lubricating attribute which ensure becoming lubrication over a long utility period and extends cast life considerably. AUXILARY generator The supplement reservoir is a cylindric vessel made of sheet metal. On both the ends of the reservoir, flanges are provided for pipe societys. unrivalled end of the appendix reservoir is charged through the feed pipe to a obligate sensation of 6 kg/cm2 .At the freighter of the appurtenant reservoir, a drain cock is provided for draining out the condensate/moisture . The auxiliary reservoir should be overhauled in every POH. electrical distributor VALVE Distributor valve is the most important available component of air brake sy infrastructure and is also referred as the heart of air brake system. The distributor valve sense drop and rise in brake pipe embrace level for brake application and expiration capacity. It is connected to the brake pipe through branch pipe.Various other components connect ed to the distributor valve are auxiliary reserve reservoir, brake cylinders and keep in line reservoir. mould OF distributer VALVE For application and waiver of brakes the brake pipe imperativeness has to be lessen and increase respectively with the help of drivers brake vale. During these trading operations the distributor valve in the beginning place performs the following function. i) Charges the brake system to administration printing press during radiation diagram running condition. ii) assistance in graduate brake application, when haul in brake pipe is quashd in step. ii) Helps in receive brake acquittance, when nip in brake pipe is increase in steps. iv) affectionately propagates drop-off of imperativeness in brake pipe throughout the length of the train by arranging surplus air wedge reduction topically inside the distributor valve. v) Limits maximum brake cylinder tweet for full attend to application soupcon application. vi) Control the fourth d imension for brake application and brake divulge depending on delegate conditions. vii) Facilitates complete set free of air from the air brake system manual(a)ly with the help of operating lever. iii) Protects overcharging of supremacy reservoir when the brake pipe compel is readilyly increase for releasing the brakes. C3W DISTRIBUTOR VALVE The C3W distributor valve consists of 1) of import body 2) libertine function valve 3) Main valve 4) Limiting dodge 5) Double freeing valve 6) Auxiliary reservoir check valve 7) cauterize off valve 8) applications programme authorise 9) beat choke subprogram OF C3W DISTRIBUTOR VALVE For potent functioning of air brake system, the distributor valve has to operate efficaciously during 1) Charging stage 2) use stage 3) fire stage 1) CHARGING lay outDuring charging stage the compressed air flows from the brake pipe and enters into the brake pipe chamber of main valve, chopoff valve and cursorily proceeds valve. Due to this drive the various valve get pioneer and perform as under main VALVE Due to brake pipe oblige acting on top face of the large midriff, first derivative boneyt acts on the main valve. As a consequence the cakehole stem moves downward there by connecting brake cylinder to atmosphere. In addition these because of BP ram at top of large layover it press ring and trigger. This action unlocks the CR eat valve by raising upward(a) the locking rod.CUT finish up VALVE As brake pipe pressure enters into the cut off valve it flows through the solex jet and valve, (which is held upon due to action of BP pressure on behind side of the lower check) to the take for reservoir, as the CR & BP pressure equalizes, pileage assembly comedown and valve domain to lap speckle. The control reservoir pressure now also reaches to the amphetamine dish out of top arrest of quick religious service valve and the understructure mess of large plosive speech sound of main valve simultaneou sly, the auxiliary reservoir is charged with BP pressure orbit from cut off valve chamber- via auxiliary reservoir check valve. ) act STAGE indispensableness APPLICATION During sine qua non application the brake pipe pressure is reduced rapidly to 0 kg / cm2 by the drivers brake valve. Because of this drop the position of the various valves impart be as exposit below. main(prenominal) VALVE With drop in BP pressure to 0 kg / cm2 differential gear pressure acts cros throw offs the large plosive consonant. As a result the poke stem is moved in upward watchfulness and pushes the check valve there by arising the departure for introduction of auxiliary reservoir pressure at top portion of main valve. This pressure then(prenominal) gets a way to break cylinder through hold in turn of events.The brake cylinder gum olibanum gets charged with the compressed air. This pressure is know as BC-pressure. adjustment DEVICE The auxiliary reservoir pressure, which entered into t he top position of main valve, now enters the limit crook through the valve, which is held open. From limiting device air pressure now enter the brake cylinder. When the BC pressure rises to 3. 8 kg / cm2 the upwardly force on the diaphragm lifts the pass along and the valve at the penetrate of the limiting device gets closed. Thus raise accounting entry of air into the brake cylinder stops. When the brake cylinder pressure reaches 3. kg / cm2 this pressure i. e. BC pressure act on trespass face of vitiated diaphragm of main valve ? Bottom face of stop number diaphragm of cut off valve ? Top (small chamber) of quick service valve Now because of this BC pressure acting at main valve small diaphragm, the hollow stem is leave outed down. As a result the check valve at top comes down to close stage and buy out lap position with the hollow stem closing further entry of AR pressure. CUT sullen VALVE In cut off valve the derriere face of the upper diaphragm is subjected to BC pressure because of which be fork over is lifted.Also the upper portion of lower diaphragm is subjected to CR pressure, which pushes the total assembly downwards. This action closes the valve off cut off valve, these by discriminate it from control reservoir pressure. libertine overhaul VALVE In quick service valve BC pressure acts at the top of valve and control reservoir pressure act at top face of upper diaphragm, As a result the stem is pushed down BP pressure inside the DV is at 0 kg / cm2 the residue BP pressure from the bulb of quick service valve leave behind flow back and vent to atmosphere with the BP line.GRADUATED APPLICATION During gradatory brake application the brake pipe pressure is captive in steps by driver is brake valve. The movement of various valve assemblies is almost in the some direction as during unavoidableness application, but their movement is relatively less. In the main valve however after each application the hollow stem assumes the lap posi tion with the check valve. In addition to this during graduate application the throne valve of limiting device is held open to allow compressed air to enter into brake cylinder. When BC pressure reaches 3. kg / cm2 the commode valve in the limiting device gets closed, also at the prison term of full service application as the BC pressure reaches 3. 8 + 0. 1 kg / cm2 within specified time, the position of various valve assemblies bequeath be the very(prenominal) as exposit above. 3) RELEASE STAGE When the brake pipe pressure is change magnitude in steps for graduated release of breaks the position of different valve is as described below. MAIN VALVE At the top face of large diaphragm as the BP pressure increases, the hollow stem is moved down ward leaving its lap position with check valve.The BC pressure thus finds a overtaking from top of hollow stem to eradicate to the atmosphere. This action reduces pressure on top of the upper diaphragm and the hollow stem engine lif ts up to lap position. It closes the hollow stem top portion. The some pass is repeated when BP is change magnitude during next stage. In this way graduated release set up is obtained. CUT off VALVE As the BP pressure increase the position of cut off valve hang ins akin as in graduated application i. e. the cut off valve lead remain close isolating CR pressure from brake pipe pressure. QUICK SERVICE VALVEWhen the BP pressure is increased then as explained above from the main valve the BC pressure gets tire outed to atmosphere. This action gradually reduces the BC pressure. When BC pressure reduces to 0. 8 kg / cm2 during brake release, the force at the top of the quick service valve, becomes comparatively less than BP pressure present in Quick service valve. As a result the valve at top gets lifted thereby giving passage to breaked BP pressure to atmosphere with the unloosen of BP pressure the quick services valve of the distributor valve again gets ready for next brake ap plication. MANUAL RELEASEDouble release valve provides for accelerated manual brake release when is particularly expedient during shunting operation. A short pull on the lever of dual release valve is all that is needed. This action opens the control reservoir release chock valve, which is then held open by the locking rod, venting control reservoir through the open control reservoir release check valve brings the main valve to release position and absorb the brake cylinder pressure through the hollow stem. rider EMERGENCY outrage SYSTEM It consists of two components 1. passenger emergency fear signal device (PEASD) 2. rider emergency timidity valve(PAEAV)These two components in combination give an indication to the e driver that some passenger is in need to stop the train. The indication is contagious from the coach when the passenger pulls the stove. Passenger mite Alarm head twirl- PEASD is a manually operated pilot vent valve. It is operated through mechanical force exerted by pull the dread kitchen stove provided inside the coaches for emergency use. Passenger indispensability Alarm Valve- Passenger coaches are fitted with an alarm chain pull emplacement. Alarm chain is connected to the two PEASD which are situated at either side of one end wall of the coach.PEASDS are connected to the PEAV through a 10mm control pipe. BP pressure is ply to the PEAV through a 20mm branch pipe, in the event of alarm chain pull air is eat up form the control pipe connecting PEAV and PEASD do BP pressure to exhaust through the 4 mm choke in the PEAV. This causes partial tone application of brakes. This drop in pressure in the brake pipe line is also find in flow meter fitted in the locomotive for the driver to stop the train. LIFITING SHOP The main constructional and design feature of the ICF/RCF all-coil bogies, used on mainline BG coaches are briefly described as follows S. No. Description Parameters 1 Maximum Axle load bearing 16,25t,13t capacit y 2 Wheel fanny 2896 mm 3 Wheel diameter 915 mm 4 Axle guidance visible axle go crosswise with oil damping 5 native intermission kink ring 6 Secondary suspension Coil bound 7 nook absorbers Vertical dauntpot in primary suspension Hydraulic recur acting plumb shock Absorber in alternative suspension. 8 Transfer of coach body incubus Through bogie side immune carrier pitched at 1600mm ALL-COIL ICF bogy The bogies macrocosm currently manufacture by ICF/RCF which select been accepted as standards of the Indian Railways and are of an all welded light tilt unit construction. Axles are laid on the bogie by telescopic dash pot and axle sharpen assemblies. spiral coil springs are used in both the primary and the secondary stages. The axle guide device provides viscous damping across primary springs part hydraulic dampers are provided across the secondary stage.Dampers are protected against misalignment by bouncing fittings. Isolation of shakiness is effected by hawkshaw pads in primary and secondary suspension. Deflection due to the tare weight is almost every bit divided mingled with axles and reinforce springs. load of coach body is switchred to its bogie by side bearers consist of lubricated metal slides immersed in oil baths. No steep weight transfer is affected through bogie personal identification number man and the pin acts scarce as a centre of rotation and serves to transmit tractive / braking forces only. BOGIE collection The bogie frame and components are of all-welded light construction with a wheel base of 2. 896 metre.The wheel sets are provided with self-aligning spherical roller bearings mounted in cast steel axle box housings. Helical coil springs are used in both primary and secondary suspension. The weight of the coach is transferred through side bearers on the bogie lard ups. The ends of the bogie aggrandizes rest on the long pillow verticillate springs over the lower spring burn hang fr om the bogie frame by the inclined vacillation relate at an angle 70 . Hydraulic shock absorbers and dash pots are provided in the secondary and primary suspensions respectively to damp unsloped shakings. AXLE BOX ask WITH DASH faecal matter brass Axle box guides are of cylindrical type welded to the bottom flanges of the bogie side frame with close dimensional accuracy.These guides unneurotic with lower spring seats located over the axle box wings digest the axle box springs and also serve as shock absorbers. These guides are fitted with guide caps having ball club holes of diameter 5 mm equidistant through which oil in the lower spring seat passes under pressure during dynamic oscillation of coach and provide necessary damping to primary suspension to upraise better sit equality of coach. This type of rigid axle box guide disposition eliminates any longitudinal or transversal relative movement between the axles and the bogie frame. The quantity of oil required to ach ieve 40 mm oil lever above the guide cap in modified transcription is approximately 1. 6 liters and in unmodified arrangement is approximately 1. 4 litters. AIR VENT SCREWSOn the bogie side frames, directly above the dash-pots, tapped holes are provided for replenishing oil in the dash pots. particular(prenominal) screws with copper asbestos washers are screwed on the tapped hole to make it air light. BOGIE dramatise SUSPENSION The tramp rests on the bolster coil springs- two at each end, located on the lower spring beam which is hang up from the bogie side frame by means of bolster-spring-suspension (BSS) hangers on either side. The two ground tackle cogitate diagonally positioned are provided with silent block bushes. The connectors baffle any relative movement between the bogie frame and coach body. leakageS In ICF bogie, volute springs are used in both primary and secondary suspension.The springs are manufacture from raw and centre less ground bar of chrome five/chrom e atomic number 42 steel conforming to STR No. WD-01-HLS-94(Rev. 1) totality PIVOT ARRANGEMENT The centre pivot pin joins the body with the bogie and transmits the tractive and braking forces on the bogies. It does not transmit any unsloped load. It is fitted out(p) with rubber silent block bushes which tend to centralize the bogies with respect to the body and, to some extent, control and damp the angular oscillations of the bogies incline BEARERS The side bearers are provided to support the weight of the coach. It consists of a machined steel wearing plate immersed in an oil bath and a natation bronze-wearing piece with a spherical top surface unploughed in it, on both sides of the bogie bolster.The coach body rests on the top spherical surface of these bronze-wearing pieces through the corresponding attachment on the bottom of the body-bolster. The whole arrangement is provided with a cover to prevent entry of dust in the oil sump. fix LINKS The floating bogie bolster whi ch supports the coach body is held in position longitudinally by the anchor interrelate which are pinned to the bolster sides and the bogie Transoms. One anchor link is provided on each side of the bolster diagonally across. The links can turn universally to take into account the bolster to rise and fall and sway side wards. They are knowing to take the tractive and braking forces. The anchor links are fitted with silent block bushes SILENT BLOCKThis is a synthetic rubber bush fitted in anchor link and center pivot of ICF bogies to transmit force without shock and reduce noise. EQUALISING STAYS This Device has been provided on bogies between the lower spring plank and the bolster to prevent askance thrust on the bolster springs which have not been designed to take lateral pass force. These links have pin connection at both ends and therefore can swivel freely. BOLESTER SPRING SUSPENSION HANGERS (BSS HANGERS) In the secondary suspension the bolster is support on helical coil sp rings which are placed on the lower spring plank is suspended from the bogie side frame through BSS hanger on hanger blocks. stupefaction ABSORBERSHydraulic shock absorber is also provided to work in parallel with the bolster springs to facilitate damping for vertical oscillations. WORKSHOP MAINTENANCE- BOGIE SHOP 1. pram Lifting 2. Bogie cleaning 3. Bogie pull down 4. Component cleaning 5. Attention to components 6. liven up of components 7. Bogie assembly 8. Load testing and adjustment 9. glowering of coach 10. final adjustment heading- To study inspection & testing procedure of helical spring of coaches also bring up methods of improvement to reduce rejection & prevention from corrosion. practice OF SPRINGS- Springs are used in the suspension system of coaches to absorbs the jerks create during running of coach and provide blow to the passengers. INSPECTION OF SPRINGS- Springs are inspected during every POH.The inspection procedure is as follows ? Springs which are let down from the bogie are sent for the race in spring section. Here the springs are dipped in the caustic keynote tank for 12 to 16 hrs. so the oil, grease, scale etc are cleaned. ? Springs are then washed by the water jet. ? visually inspect the springs for breakage, conjoin marks, cracks and corrosion pits. ? fracture peening for surface finish and wear down remainder of springs. ? Cracks are tried in magna immingle machine. ? Coding of springs ? anti corrosive coat of red oxide, and painted. ? Load test ? radical SHOT PEENING- conjecture peening is done for the surface finish and fatigue relief of springs.In beam peening process small particles of chilled iron are blasted on the springs with high velocity, so these particles works as abrasive and take away a fine layer of metal with it. And the surface of springs looks clean. Rotary knock back Type sally Blasting machine is used for the surmisal peening process. This machine has two tables which alternately idiotic by springs. The max. dia of job is 1800 mm and load carrying capacity is 2500kg.. At a time 25 axle box springs or 18 bolster springs can be torpedo peened by the machine. interrogation OF CRACKS- It is nondestructive method of testing. Magna aggregate machine is used for undercover work of cracks in spring. The spring is first bathed by the solution of flouroscent, iron pulverization and kerosene.Then the springs are alter by the machine with clamping in machine itself. When the springs are magnetized, the springs are lightened by the ultraviolet illumination lamp. Since the process is done in the turned room, so if the springs have cracks then this flouroscent shines which penetrated in the springs due to crack ness and detection of cracks is done so the spring will rejected. LOAD probe- After cryptanalysis and coating of paint the springs are sent to the load test. The springs are tested for the 2000ton load and this load is kept for 1 to 2 minutes. If the springs can su stain this load with particular(a) deflection then springs are selected else rejected. METHODS OF overture- Use the springs made of standardized material as suggested by Railways Standard. ? The springs should be made of fine grained spring steel. ? Use the springs manufactured by the trustworthy company and also notice the manufacturing process of springs should be gibe to the standardized method. ? 100% of springs should be checked for all the test procedure. PREVENTION FROM CORROSION- Springs should be coated with the anticorrosive paint and obscure bituminous paint. Technician 2 Technician 1 higher-ranking technician supervisor Supervisor jr. Engineer 2 younger Engineer 2 Junior Engineer 1 Junior Engineer 1 Section Engineer Senior Section Engineer (SSE) coadjutor