Carriage & Wagon repair

Workshop,Bangladesh
Railway,Pahartali,Chittagong
 An Overview of Carriage and Wagon Repair Workshop,
Bangladesh Railway, Pahartali, Chittagong

BY
Emamul Ahasan Plabon, Muhammad Taharat Galib, Mehedi Hasan Tusar, Amir
Hamza Limon, Fazlay Rabbi, Abdul Hannan Talukdar, Ikhlas Hossain, Likhan
Kanti Das

Department of Mechanical Engineering, Chittagong University of Engineering and Technology,

Chittagong-4349, Bangladesh
 INTRODUCTION

BANGLADESH RAILWAY

Bangladesh Railway is the state-owned rail transport agency of Bangladesh .It operates and
maintains the entire railway network of the country. BR is controlled by the Directorate General of
Bangladesh Railway under the Ministry of Railways along with Bangladesh Railway Authority
(BRA) and which works for policy guidance of BR.

Key features of BR are the coexistence of several gauges, Broad gauge, Metre gauge and dual
gauge, and the separation of the system by the Jamuna River (Brahmaputra) into a Western and
Eastern Zone of operations with only one bridge, the 2003 Jamuna Bridge, connecting the two
zones. Bangladesh Railway covers a length of 2,855 route kilometres and employs 34,168
people. BR operates international, inter-city and suburban rail systems on its multi-gauge
network. It also owns coach production facilities.

BANGLADESH RAILWAY WORKSHOP

Bangladesh Railway has sheds, depots and workshops for maintenance. Rolling Stock,
Locomotives are maintanied in 3 places viz shed shop & CLW. Carriage & Wagons are
maintained in two places i.e. in C&W Depot & workshop.

Locomotives are maintained in following workshops :

Central Locomotive Workshop at Parbatipur, Dinajpur.

Diesel Workshop at Pahartali, Chittagong. Diesel
Workshop, Dhaka.
Diesel Workshop at Parbatipur, Dinajpur.

Carriages & wagons are maintained in following workshops

C & W Shop at Saidpur, Nilphamari.

C&W shop at Pahartali, Chittagong.

There are two main shops. Carriage and Wagon shop. Other shops are subsidiary of these two
main shops.
 Fig:Workshop location diagram

The shops are as follow.

1. Carriage shop
2. Wheel shop
3. Wagon shop
4. Foundry shop
5. Welding shop
6. CHR shop
7. Machine shop
8. Tool room shop
9. Mill wright shop
10. Progress shop
11. Paint shop
12. Smithy shop
13. GOH shop
14. Training shop
 CARRIAGE SHOP

When a damaged rail car is sent to repair in this railway industry at first it is received by the
carriage shop. Then the carriage shop identifies the problems and defects of that car. If the
carriage has to be done heavy repair, this industry performs it. Actually in this industry, heavy
repair is done. After marking the damages ,the carriage shop decides that which part of that car is to
repaired. It also disintegrade all parts of the rail car. And after disintegrading, it sends different faulty
parts in different other shop according to it’s requirements. There are different types of coach. At
first carriage shop makes a schedule of repairing that carriage. The schedule includes all routine of
repairing from itsentry to leave as a finished product.
Carriage Shop deals with the repair of carriages following schedules. Generally, three schedules are
followed according to measuring the condition of a carriage and its service life. They are:

LE takes about 15 days to be completed, POH takes about 27 days and GOH takes about 45 days.
It takes 1 month to repair intercity rail and takes 18 days to repair mail express. Besides CHR also
performs special service when that is needed badly.
 Figure: a heavily damaged carriage

Figure: Carriage shop

Different types of plates and bars are used to repair frame and body. In underside of a carriage
middle bar (half inch thick) is used longitudinally and cross bar are used with it making 90 degree
angle. The sole bar is joined on the two sides parallel with middle bar. The head stock and tailstock
are attached with every carriage to connect one carriage to another. The steel plates that are used as
body is 332 mm thick and 116 mm thick when used as roof sheet. The dove tail sheet with 30 degree
angle is used as floor sheet. Formica sheet is used as inside body. Over the dovetail sheet of the
basement a cement layer is used which is ClH 13Mg3O9 (Magnesium Oxy chloride)
The types of carriages are given below:
WJC(Having gangway bridge with sleeper)
JC(Cabin car)

WJCC(Gangway bridge with chair car, AC)

WEC (Gangway ridge with economic class)
SLR(Second class luggage bench)
WJCCDR(Dinning car)

GOH SHOP

In GOH Shop we have seen Buffer System and its different parts (Yoke side, Hook side.. etc): The
two major braking system of train -1. Air Brake 2. Vacuum Brake. Introduction of both Leveling
and Cambering and their importance were both demonstrated to us.
In carriage heavy repair shop mainly heavy damaged coach is repaired. When any coach is
reached in progress shop, the coach is under inspection. If it seems to heavy damage then it is send
to CHR shop.

When any heavy damage coach is send to CHR shop, the workers at first cut its side panel. Then it
needs to level.

Figure: A heavily damaged coach

The plate which is used in CHR shop is given bellow:

 116 plate(floor sheet for passenger coach, roof, door cover)
332 plate(side panel and bathroom)
1 가가
plate(for z pillar)
8
Checkered plate(for standing and gang way bridge)
316 plate (cross bar, L angle, shatter extend)
1 가가
4
plate(cement molding)
1 가가
plate(head stoke)
2
1 가가
plate(head stoke collar)
8

There are 3 over head crane to lift the body and other purpose. There are various types of
machine in CHR shop. There has a multi drilling machine for the better work. There has also a
plate cutting machine.

Figure: Guilloting shearing machine

Railway Air Brake

A railway air brake is a railway brake power braking system with compressed air as the
operating medium. Modern air brake systems serve two functions:
 The service brake system, which applies and releases the brakes during normal
operations, and
The emergency brake system, which applies the brakes rapidly in the event of a brake pipe failure or an emergency
application by the engine operator (generally referred to as the automatic brake).

Air storage tanks are filled with compressed air by the compressor, which is powered by the
engine. When the driver steps on the brake pedal, or treadle valve, this allows air from the
storage tanks to flow into the cylinder, pushing the piston down the cylinder.

Figure: Air Break System

Vacuum Brake

The vacuum brake is a braking system employed on trains and introduced in the mid-1860s. A
variant, the automatic vacuum brake system, became almost universal in British train equipment
and in countries influenced by British practice. Vacuum brakes also enjoyed a brief period of
adoption in the United States, primarily on narrow-gauge railroads. Its limitations caused it to be
progressively superseded by compressed air systems starting in the United Kingdom from the
1970s onward. The vacuum brake system is now obsolete; it is not in large-scale usage anywhere in
the world, other than in South Africa, largely supplanted by air brakes In Bangladesh there are some
vacuum breaks still exist but air break has replaced it.

How Vacuum Break Works

A vacuum cylinder is provided underneath every railway coach. When the driver applies the
brakes, he destroys the vacuum from the engine by opening the driver's vacuum brake valve
connected to the train pipe. The resulting atmospheric pressure operates all vacuum cylinders
upwards. This causes brake rigging and brake blocks grip the wheel tyre. When the vacuum
brake valve comes to the normal position, a vacuum is recreated and the brakes are released.
 Figure: Vacuum Break

Buffer (Railway Transport)

A buffer is a part of the buffers-and-chain coupling system used on the railway systems of many
countries, among them most of those in Europe, for attaching railway vehicles to one another.

Fitted at the ends of the vehicle frames, one at each corner, the buffers are projecting,
shock-absorbing pads which, when vehicles are coupled, are brought into contact with those on the
next vehicle. The draw chain used between each pair of vehicles includes a screw which is
tightened after coupling to shorten the chain and keep the buffers pressed together. Such is known
as a 'screw coupling'. Historically, coupling chains were no more than that, a short length of heavy
chain (typically three links long) with no adjustment. These would result in a 'loose-coupled
train' in which the buffers of adjacent vehicles would only touch when the coupling chain was fully
slack, such as when being pushed or going down hill
Figure: Buffer of rail transaction

After repairing the other shops send every repaired parts to the carriage shop. Then carriage shop
checks them and ensures that is safe or not .If it is not seem too safe, CHR shop again repairs it and
if it is safe then the proper steps are taken to assembly. After assembling, again it is check that the
carriage is safe and prepared to install.

Figure: Repaired Train ceiling

There are some specifications that they can identify the repaired shop even rails path. Next repair
date, which type that is and many others. There are also some specifications that are defined by
color.

Figure: roaster for scheduled maintenance

 WHEEL SHOP

Introduction On Wheel

A train wheel or rail wheel is a type of wheel specially designed for rail tracks. A rolling
component is typically pressed onto an axle and mounted directly on a rail car or locomotive or
indirectly on a bogie,). Wheels are cast or forged (wrought) and are heat-treated to have a
specific hardness. New wheels are trued, using a lathe, to a specific profile before being pressed
onto an axle. All wheel profiles need to be periodically monitored to ensure proper wheel-rail
interface. Improperly trued wheels increase rolling resistance, reduce energy efficiency and may
create unsafe operation

Figure: Rail wheel

Types Of Wheel

Bangladesh Railway(BR) is familiar with two types of wheel. They are_

Solid type
Tire grade type
 Solid Type

This type of wheel made by steel. There is no chance to repair this wheel after damaging
rather replace with another wheel.

Figure: solid type wheel

Tire Grade Type

This type of wheel typically consists of two main parts: the wheel itself, and the tire (or tyre)
around the outside. A rail tire is usually made from steel, and is typically heated and pressed onto the
wheel, where it remains firmly as it shrinks and cools. Monobloc wheels do not have
encircling tires, while resilient rail wheels have a resilient material, such as rubber, between the
wheel and tire.

Figure: Tire grade type wheel

Tire Installation

The tire is a hoop of steel that is fitted around the steel wheel centre.

Figure: A tire of a wheel

The tire is machined with a shoulder on its outer face to locate it on the wheel center, and a
groove on the inside diameter of the flange face. The inside diameter of the tire is machined to be
slightly less than the diameter of the wheel center on which it is mounted, to give an interference fit.
The tire is fitted by heating to a controlled temperature, avoiding overheating. This causes the tire to
expand. The wheel center, usually already mounted on the axle, is lowered into the tire which is
flange side up. The tire cools, and the retaining ring (a shaped steel bar rolled into a
hoop) is fitted into the groove.

Figure: Furnace for heating of wheel

The tire is primarily held in place by its interference fit. The shoulder on the outside and the
retaining ring also keep the tire in place if the interference fit is lost. This is most often due to
severe drag braking down a gradient, or due to an error in the machining.

Removal of a worn tire is by machining out the retaining ring and heating the tire to relax the
interference fit

Figure: Tire installation by heat treatment

Wheel Profile

In wheel shop wheels are from bogie shop and wagon shop. At first wheels are free from its
shaft. Standard shaft diameter is 41 inch. There are several types of bogie is repaired in
2
workshop. They are given bellow.

PHT type.
Hungry type.
BC type.
SKFC type.
 8''×41 가가 plain bearing.
4
NSKBWD type.
Iranian.
Kinki.
Railcar.
Locomotive.

Above all this type, PHT and Iranian is passenger type. The diameter of a locomotive wheel is
about 40inch. Iranian and PHT type wheel diameter is about 730 millimeter. NSKBWD wheel
diameter is about 762 millimeter. BC china type wheel diameter is about 660 millimeter. BC type
is defined as C class. And SKFC is defined as B class. Generally a wheel configuration is given
bellow:

Full tier 724 mm (PHT) and condemned size is 660 mm.

Full tier 730 mm (Iranian) and condemned size is 670 mm.
가가
Wheel flange 1′′ and condemned size is 5
8

Allowable wheel diameter difference between two wheels at the same pair is 0.5 millimeter.
Allowable wheel diameter difference between two pair wheels at the same bogie of coach is 5
millimeter. Allowable wheel diameter difference between two bogies of a coach is 10 millimeter.

Causes Of Damage Of Wheel

The most usual cause of damage is drag braking on severe gradients. Because the brake blocks
apply directly on the tire, it is heated up, relaxing the interference fit. It is not feasible to fit the tire
with such a heavy interference as to eliminate this risk entirely, and the retaining ring will ensure
that the tire can only rotate on the wheel center, maintaining its alignment. In rare instances
the rotation could be so severe as to wear the retaining ring down till it breaks, which
 could result in derailment.

Figure: A damaged wheel

Defects And Measurement

This specification details the allowable limits for the inspection of all rail vehicle wheels for
various tread and flange defects.

1. Thermal cracks: Thermal cracks are the result of alternate heating and cooling of the
wheel tread and rim area, and originate from metallurgical changes in the wheel material.

Thermal cracks are the most severe form of wheel defect.

Figure: Thermal crack

2. Rolling contact fatigue: Rolling contact fatigue cracks is caused by repeated contact stress during the rolling motion.
Rolling contact fatigue cracks usually develop on rhe tread surface and are generally not oriented perpendicular to the
running direction. This type of defect can lead to spalling.
 Figure: Rolling contact fatigue

3. Sub surface fatigue: Sub surface fatigue cracks initiate from metallurgical defects in the wheel. The cracks generally
develop 3 to 25 mm below the tread surface in the region of maximum shear stress in the wheel/rail contact area. Sub surface
defects are normally identified by ultrasonic testing; however there are three visual ways to identify a sub surface fatigue
defect. Cracks appear on the tread or flange during wheel turning.

Figure: Sub surface fatigue

4. Arrises

An aris is formed when flange metal has rolled towards the tip of the flange causing a
 step with a sharp point at the flange tip.

Figure: Arrises defect

5. Flange Wear/Defects:

Thin flange: Collar become thinner from it’s original profile.

Figure: Thin flange defect

The recommended method for detecting a thin flange is using a flange height and thin flange
gauge. A thin flange will be detected when the end of the gauge touches the tread surface of the
wheel.

Figure: Thin flange measurement

 Sharp Flange
Corner of the flange became sharp.
Measurement : Same as thin flange(tyre profile gauge)

Figure: sharp flange measurement

Deep Flange Or Hollow Tyre
A deep groove is formed on the inner sight of the wheel.

Figure: deep flange or hollow tyre defect

Measurement : Same as thin flange(tyre profile gauge)

6. Manufacturing Defects

This type of defect generally occurs on the wheel web and can result in a fatigue crack
which propagates circumferentially around the web. In other cases, defects have led to
large pieces of the flange falling off in service

a b

Figure: Badly turned wheel resulting incorrect turning process(a)and mill feed(b)

7. One Wheel Become Smaller In Diameter From Another In An Axel

Inspection for overhanging brake blocks or misaligned brake gear must be carried out with the
brakes applied.

Measuring Instrument: tyre profile gauge

 Figure:diameter measurement(tyre profile gauge)

Wheel Operation

Wheel Turning

The wheel turning lathe is an essential tool for fleet operators to enable wheelsets to be kept in
condition without the need to remove from the vehicle for machining. The underfllor lathe
machines either a single or a pair of wheelsets simultaneously, dependent on its configuration.

Figure: wheel turning lathe machine

Axle box supports (internal or external) and holding down clamps are used to provide a datum for
the machining of the wheel, ensuring that the finished profile has the best possible roundness and
concentricity as fitted on the bogie.
 Figure: lathe machine (railway workshop,pahartoli,ctg)

Axle Journal Turning Burnishing Machine(AJTB)

Main operation of this machine is turning and reducing diameter of wheel.

Figure: A J T B machine (railway workshop,pahartoli,ctg)

Rolling Machine

Rolling is one of the key stages of railway wheel hot forming process. In this work, a
three-dimensional finite element analysis on wheel vertical rolling process based on some
strategies proposed has been carried out by using FE code SuperForm. In modeling, a virtual
mandrel is exploited in the hub hole to keep the wheel central instead of the guide rolls and
centering rolls. Some features of the wheel forming are deeply investigated such as the rim diameter
expanding, the rim lateral spreading, the metal flow in the circumferential direction, and the
stresses distribution. The results show that (1) the rim radius expanding mainly occurs in the two
affected zones before and after the back roll deformation zone; (2) the rim metal has flow trend in
the circumferential direction during rolling, the metal of the intersection area, between the tread and
the rim external side surface has the largest relative angular displacement; and (3) the tensile
stresses of the web both in radial and circumferential directions during rolling result in the web
thickness decreasing by about 3 mm for the investigated wheel. The simulations results reveal the
forming mechanisms of wheel rolling, laying the basis for designing and optimizing railway wheel
forming process.

Figure: Rolling machine (railway workshop,pahartoli,ctg)

Wheel Boring

Boring is an operation to enlarge and finish holes accurately. This may be done on a lathe or a
milling machine.

Figure: Boring operation of a railway wheel

Boring is a machine operation in which the work is in contact with a single point tool.
 Figure: Vertical boring machine (railway workshop,pahartoli,ctg)

Bearing Fitting With Wheel

After completing all the operation tapered roller bearing or brush bearing is fitted with the wheel
axel. Before fitting roller and bearing must be cleared with suitable liquid(kerosine).

Figure: Uncleaned roller Figure: Tapered roller bearing fitted with axle
 Figure: Fixing the bearings with wheel exel

Figure: Fitting section of railway workshop,pahartoli,ctg

Inspection Of Wheel

After finishing all operation procedure and before deliver the wheel inspection is needed. To
maintain this viability, ensuring train safety and integrity is key. Stringent regulations are
imposed on the inspection of train wheels and axles in both the manufacturing and service.

Figure: Inspection list of railway workshop pahartoli,ctg

After finishing all operation relating with wheel, wheels will be delivered to the carriage shop for
assembling with wagon or bogie.
 WAGONSHOP

In wagon shop administration maintain one schedule known as POH. POH schedule maintain 31
2 years to return the wagon into workshop. There maintain another schedule called special
schedule in case of any damage of wagon. It does not follow any schedule. There are various types
of wagon. They are:

Tank wagon
Covered wagon
Flat wagon
There has a code number that indicate which type of wagon it is. For example, BXTK, BFCT BC
BKC

Figure: a BXTK 60185 type wagon

There are 3 parts in a wagon.

Bogie
Body
Buffer
There are several types of bogie. They are:

Rubber chevron bogie.

Diamond type bogie.
Right control bogie.
WD bogie.
 Non-standard bogie.
In pahartali wagon workshop most repaired bogies are rubber chevron bogie, diamond type

Bogie, right control bogie. In wagon shop of all section, section 3 is used for various testing.

There are two brake systems for wagon.

Air brake system.

Vacuum brake system.
In air brake system the controlling device operates in the cylinder and in vacuum brake system is
controlled by DV(distribution valve) valve. In air brake system air is force in 5barfrom testing rig.
This testing rig is attached with main compressor with 10bar. Air is entered into the cylinder from
testing rig at 3.8bar. In a locomotive after entering air it takes 18-30s to create a brake. Again it
takes 45-60s to release the brake.

Figure: Testing rig.

There has a change over valve. If load is applied on the bogie, then pressure is increased. So the
valve head touch vertical helical spring. Then it pressed air hardly. As a result brake is also hard.
 MACHINE SHOP

A machine shop is a room, building, or company where machining is done. In a machine

shop, machinists use machine tools and cutting tools to make parts, usually
of metal or plastic (but sometimes of other materials such as glass or wood). A machine shop can be
a small business (such as a job shop) or a portion of a factory, whether a toolroom or a
production area for manufacturing. The parts produced can be the end product of the factory, to be
sold to customers in the machine industry, the car industry, the aircraft industry, or others.

Pahartali Railway Carriage & Wagon Workshop, Chittagong has a machine shop where different
parts needed for repair and maintenance are prepared and machined by the skilled labor in
different types of machine like Lathe machine, milling machine, shaper machine, planer
machine. With these machines several types of operations are done like

1.Cutting

2.Profiling

3.Grinding

4.Boaring

5.Drilling

6.surface smoothing

7.Thread cutting (internal and external)

8.Facing

Machine shop of Pahartali Railway Carriage & Wagon Workshop, Chittagong mainly works with
following jobs

1) Dump plate
2) Bolt
3) Fill
4) Break bearing
5) Break block
6) Coupler
7) Side bearer
8) Brush bearing
9) Axle box
10) M/s cutter
11) Chamber bracket
12) Water tank ring
13) Shutter guard rail stopper
 14) Door hinge
There are three major sections in this machine shop.

Turning section

Turning sections is an important section in the machine shop.in this section different operations
like turning, boring, cutting, threat cutting etc.

Fig: turning of a screw

 Fig: Thread cutting on a screw

Machining sections:

In machining sections machining of different parts is performed .machining includes

turning, facing, boring, drilling, creating hole etc
Fig: before and after machining of a brush bearing
Marking and fitting sections

In fitting section cutting, filling, measuring, marking of different parts are done with the help of
various hand tools.

Fig: before and after operation of the workpiece in a shaper

Fig: operations in fitting shop

For these purposes different machines are used. These types of machines that are used in
machine shop are:

1)Capstan Lathe
2)Centre Lathe
3)Turret Lathe
4)Shaper
5)Planer
6)Screwing machine
7)Milling machine
8)Grinding machine
9)Iron Separator (For removal of white metal)
10)Measuring devices: Thread gauge, divider etc.

Capstan lathe

Capstan lathe is one of the types of semi-automatic lathe. In semi-automatic lathes machining
operations are done automatically. Functions other than machining like loading and unloading of
job, positioning of tools coolant operations are done manually.

Fig: capstan lathe machine

Centre Lathe:

Machine equipment for cutting metal wherein a workpiece is held and rotated while a
firmly-placed tool is applied in order to create a circular product. Flat surfaces may be made by
facing, screw cutting, boring and drilling procedures. Workpiece is typically held in a chuck or by
two centers.

Fig: Centre lathe machine

Turret Lathe

The turret lathe is a form of metalworking lathe that is used for repetitive production of
duplicate parts, which by the nature of their cutting process are usually interchangeable.

Fig: turret lathe machine

It evolved from earlier lathes with the addition of the turret, which is an indexable toolholder that
allows multiple cutting operations to be performed, each with a different cutting tool, in easy, rapid
succession, with no need for the operator to perform set-up tasks in between, such as installing or
uninstalling tools, nor to control the toolpath.
 Difference between centre lathe and capstan/ turret lathe:

Centre lathe Capstan/turret lathe

1 It is a manually operated lathe It is a semi-automatic lathe

2 It has only one tool post tool changing time is Front and rear tool posts are available.
more Tool changing time is less

3 It has tail stock It has turret head instead of tail stock

4 Only one tool can be fitted in the tail stock Six different tools can be fitted in the turret
head.

5 Number of speeds is less Number of speeds is more

6 Tool changing time is more Tool changing time is less

7 The machine should be stopped for changing tool Tool can be changed without stopping the
machine

8 It is not suitable for mass production It is suitable for mass production The

9 No feed stops to control the tool tools are controlled by feed stops The

10 The tool is centered manually after changing the tool is centered automatically
tool

11 Only one operation is done at a time More than one operation can be done at a time
Functions of different parts of a lathe machine:

Fig: Different parts of a lathe

Parts Functions
Apron Front part of the carriage assembly on which the carriage hand wheel is
mounted

Bed Main supporting casting running the length of the lathe

Carriage Assembly that moves the tool post and cutting tool along the ways

Carriage A wheel with a handle used to move the carriage by hand by means of a rack
Hand wheel and pinion drive

Chuck A clamping device for holding work in the lathe or for holding drills in the
tailstock.

Compound Movable platform on which the tool post is mounted; can be set at an angle to
the work piece. Also known as the compound slide and compound rest.

Cross Feed A hand wheel or crank that moves the cross-slide by turning a screw. Also the
action of moving the cross slid using the cross feed hand wheel.

Cross-slide Platform that moves perpendicular to the lathe axis under control of the cross-
slide hand wheel
 Headstock The main casting mounted on the left end of the bed, in which the spindle is
mounted. Houses the spindle speed change gears.

Lead screw Precision screw that runs the length of the bed. Used to drive the carriage
under power for turning and thread cutting operations. Smaller lead screws
are used within the cross-slide and compound to move those parts by precise
amounts.
Spindle Main rotating shaft on which the chuck or other work holding device is
mounted. It is mounted in precision bearings and passes through the
headstock.

Saddle A casting, shaped like an "H" when viewed from above, which rides along the
ways. Along with the apron, it is one of the two main components that make
up the carriage.

Tailstock Cast iron assembly that can slide along the ways and be locked in place. Used
to hold long work in place or to mount a drill chuck for drilling into the end
of the work.

Toolpost A holding device mounted on the compound into which the cutting tool is
clamped

u
Shaper
A shaper is a type of machine tool that uses linear relative motion between the workpiece and a
single-point cutting tool to machine a linear toolpath. Its cut is analogous to that of a lathe, except
that it is (archetypally) linear instead of helical.

Fig: shaper machine

Working Principle of Shaper

A single point cutting tool is rigidly held in the tool holder, which is mounted on the ram. The work
piece is rigidly held in a vice or clamped directly on the table. The table may be supported at the
outer end. The ram reciprocates and thus cutting tool held in tool holder moves forwards and
backwards over the work piece. In a standard shaper, cutting of material takes place during the
forward stroke of the ram the backward stroke remains idle. This is obtained by "Quick Return
Mechanism". The depth of the cut is adjusted by moving the tool downwards towards the workpiece
Planer
A planer is a type of metalworking machine tool that uses linear relative motion between the
workpiece and a single-point cutting tool to cut the work piece. A planer is similar to a shaper, but
larger, and with workpiece moving, whereas in a shaper the cutting tool moves.

Fig: planer machine

Screwing machine
A screwing machine is used for screwing. A motor is employed to drive the screwing tools by belts
and pully system.

Fig: Screwing machine

Milling machine:
Milling is the process of machining flat, curved, or irregular surfaces by feeding the workpiece
against a rotating cutter containing a number of cutting edges. The milling machine consists
basically of a motor driven spindle, which mounts and revolves the milling cutter, and a
reciprocating adjustable worktable, which mounts and feeds the workpiece. Milling machines are
basically classified as

a)Vertical milling machine b)Horizontal milling machine

These machines are also classified as knee-type, ram-type, manufacturing or bed type, and
planer-type.

Vertical milling machine:

 In the vertical mill the spindle axis is vertically oriented. Milling cutters are held in the spindle
and rotate on its axis. The spindle can generally be extended (or the table can be raised/lowered,
giving the same effect), allowing plunge cuts and drilling. There are two subcategories of vertical
mills: the bed mill and the turret mill.

Fig: vertical milling machine

A turret mill has a stationary spindle and the table is moved both perpendicular and parallel to the spindle axis to
accomplish cutting. The most common example of this type is the Bridgeport, described below. Turret mills often have a
quill which allows the milling cutter to be raised and lowered in a manner similar to a drill press. This type of machine
provides two methods of cutting in the vertical (Z) direction: by raising or lowering the quill, and by moving the knee.

In the bed mill, however, the table moves only perpendicular to the spindle's axis, while
the spindle itself moves parallel to its own axis.
Horizontal milling machine:
A horizontal mill has the same sort but the cutters are mounted on a horizontal spindle (see Arbor
milling) across the table. Many horizontal mills also feature a built-in rotary table that allows
milling at various angles; this feature is called a universal table. While end mills and the other
types of tools available to a vertical mill may be used in a

Fig: horizontal milling machine

horizontal mill, their real advantage lies in arbor-mounted cutters, called side and face mills,
which have a cross section rather like a circular saw, but are generally wider and smaller in
diameter. Because the cutters have good support from the arbor and have a larger cross-sectional
area than an end mill, quite heavy cuts can be taken enabling rapid material removal rates. These are
used to mill grooves and slots. Plain mills are used to shape flat surfaces. Several cutters may be
ganged together on the arbor to mill a complex shape of slots and planes. Special cutters can also
cut grooves, bevels, radii, or indeed any section desired. These specialty cutters tend to be
expensive. Simplex mills have one spindle, and duplex mills have two. It is also easier to cut gears
on a horizontal mill. Some horizontal milling machines are equipped with a power-take-off
provision on the table. This allows the table feed to be synchronized to a rotary fixture, enabling the
milling of spiral features such as hypoid gears.
Grinding machine

A grinding machine, often shortened to grinder, is any of various power tools or machine tools
used for grinding, which is a type of machining using an abrasive wheel as the cutting tool. Each
grain of abrasive on the wheel's surface cuts a small chip from the workpiece via shear
deformation. Grinding is used to finish workpieces that must show high surface quality (e.g., low
surface roughness) and high accuracy of shape and dimension.
 Fig: Grinding machine

As the accuracy in dimensions in grinding is of the order of 0.000025 mm, in most applications it
tends to be a finishing operation and removes comparatively little metal, about 0.25 to
0.50 mm depth. However, there are some roughing applications in which grinding removes high
volumes of metal quite rapidly. Thus, grinding is a diverse field.

Iron separator:
Iron separator is used for the removal of the white metal from the surface of parts.
Measuring devices: Thread gauge, divider etc. measuring devices are used for measuring in
fitting section.

Fig: measuring devices

Tool Room Shop:

Different kinds of machine tools are prepared & recycled through three sections in a tool room.
These three sections are done respectively one after another.

a) Machine section:

1) Parting 5) Wheel shop tool

2) Facing 6) Tire grubbing

3) Turning 7) Swan-neck rougher.

4) Boring

b) Fitting Section:

1) Filling 2) Finishing 3) Fitting

c) Heat treatment Section:

1) Hardening 2) Tempering

3) Annealing 4) Normalizing & coining.

For cutting tool, high speed steel is used commonly. But at the absence of high speed steel mild
steel is used placing diamond/carbide part at the apex of it. Because high speed steel got buckled in
phase of water. After completing machining and fitting section heat treatment process carry on.
This is most important section for desired products. Required furnaces such as gas furnace,
electric furnace and blower are used in this process. The metal has been heated at high
temperature approximately 724C. For reducing brittleness, metal is being tempered at critical
temperature (100F-200F) for 20 minutes depending upon the types of carbon percentage. Then the
metal is cooled down slowly. The annealing is done with the help of Calcium Carbonate.
Normalizing carry on depending upon the type of metal.
For carbon steel, oil bathe is used.
For mild steel, water bathe is used.
For high speed steel, dry air is used.

The machine available in tool room such as Chaser grinding m/c, shearing m/c, Horizontal
milling boring m/c, center lathe m/c, Enrobing mc, Power saw for cutting steel/rod, shaper mc,
Universal cutter grinding mc, special purpose mc which is used for both turning and threading.
Using the presence of this available instrument, the following types of tools are prepared in tool
room shop
1) Steak
2) Side cutter
3) Thread cutter
4) Boring tool
5) Internal screwing
6) Side cutter right hand
7) Swan-nick v
8) Parting
 FOUNDRY SHOP

In foundry shop, manpower sanction 65 employee but now on roll 42. They works under an SSE in
charge. There are two sections in foundry shop. One is known as ferrous section and another is
known as non-ferrous section. In ferrous section brake block is produced and in non-ferrous
section plane bearing is re-metaling so that the surface become antifriction. This antifriction
metal known as white metal. White metal contains 80% led, 1% copper, 6% Sn, 13%Sb. The
material of brake block is gray cast iron. There are several types of brake block produce in
ferrous section. The list is given bellow:

Passenger bogie brake block:

China/Iran type.
F type (Pahartoli type).
Diesel brake block.
Wagon brake block:
F type (Pahartoli type).
BFCT type(weight is 10.0kg)
Indian.
China.
BC type.(10 kg)
WD type.(11kg)
Mass production in ferrous section is Diesel brake block. The weight of a diesel brake block is
12.70kg, F type is 10.5okg, BFCT, Iranian type

Figure: Foundry shop

Common Tools Used in Foundry Shop

Shovel

It is used for mixing and tempering the molding sand for moving the sand from one place to
another place in the foundry.

Figure: Shovel

Riddle or screen

It is used for cleaning the molding sand.

Vent wire

It is used to pierce holes in the rammed sand to provide artificial vents which permit the easy
escape of stream and gases generated by the hot metal in contact with the sand.
Rammer

It is wooden/metallic tools used for packing and ramming the sand in the mold.

Figure: Rammer

Slick

It is used for repairing and finishing the mold.

Figure: Slick

Lifter

It is used for smoothing deep sections of mold and removing loose sand from pockets of mold.
Swab

A simple swab is a small brush made of flax or hemp fibers. It is used for applying water to the

Mold pattern.

Bellows

These are used to blow loose particles of sand from the cavities and surface of the mold.

Sprue cutter or sprue pin

A spree cutter is a tapered wooden or metallic peg or pin. It is forced into the top part of the mold at
the correct position. When the peg is withdrawn.

Trowel

The trowels consists of a metal blade with a wooden handle.it is used for finishing and repairing
mold cavities as well as for smoothing over the parting surface of the mold.
Gate cutter

A Gate cutter is a u-shaped piece of thin sheet.it is used to cut the opening that connects the spare
with the mold cavity to act a passage for the hot metal.

Figure: Gate cutter

Draw spike

A draw spike is a pointed steel rod, with a loop at one end .it is driven into a wooden pattern to
hold it and used for removing the pattern from the mold.

Figure: Draw spike

Clamps: The clamps are used for holding the cope and drag of the mold.
 Figure: Clamps

Smoother

It is used for smoothing and finishing the mold.

Molding Box

The sand molds are prepared in a specially constructed box called molding box, which are open at
top and bottom. They are made in two parts, held in alignment by dowel pins. The top part is called
cope and the lower part as drag. If the box is made in three or more parts, the intermediate part is
known as cheek. These box can be made of either wood or metal.

Figure: Molding box

Core Making
Core making much like molding, except that the core sand is placed in a core box. It can be
blown up into the box, rammed or packed by hand then dried up.

Sand Mixing

Molds made of sand are relatively cheap, and sufficiently refractory even for steel foundry use .In
addition to the sand, a suitable bonding agent (usually clay) is mixed or occurs with the sand .The
mixture is moistened, typically with water, but sometimes with other substances, to develop the
strength and plasticity of the clay and to make the aggregate suitable for molding.

Cupola furnace

A cupola furnace is a melting device used in foundries that can be used to melt cast iron, Ni resist
iron and some bronzes

For many years, the cupola was the primary method of melting used in iron foundries.

The cupola furnace has several unique characteristics which are responsible for it is widespread
uses as a melting unit for cast iron.

Cupola furnace is employed for melting scrap metal or pig iron for production of various cast iron.

It is also used for production of nodular and malleable cast iron .Itn is available in good varying
sizes.

The main considerations in selection of cupolas are melting capacity, diameter of shell without
lining or with lining, spark arrest.

Figure: Cupola Furnace.

Different types of patterns:

The common types of patterns are:

Single piece pattern

Split piece pattern
Loose piece pattern
Gated pattern
Match pattern
Sweep pattern
Cope and drag pattern
Skeleton pattern Shell
pattern
Follow board pattern

Figure: Single piece, Split, Match-plate, Cope and Drag Pattern

Single piece pattern

This is the simplest type of pattern, exactly like the desired casting. For making a mould, the
pattern is accommodated either in cope or drag.

Split pattern

These patterns are split along the parting plane (which may be flat or irregular surface) to
facilitate the extraction of the pattern out of the mold before the pouring operation. For a more
complex casting, the pattern may be split in more than two parts.

Loose piece pattern

When a one piece solid pattern has projections or back drafts which lie above or below the
parting plane, it is impossible to with draw it from the mold. With such patterns, the projections are
made with the help of loose pieces. One drawback of loose feces is that their shifting is possible
during ramming.
 Figure: Loose piece pattern

Gated pattern

A gated pattern is simply one or more loose patterns having attached gates and runners.

Because of their higher cost, these patterns are used for producing small castings in mass
production systems and on molding.

Figure: Gated pattern

Match plate pattern

A match plate pattern is a split pattern having the cope and drags portions mounted on opposite
sides of a plate (usually metallic), called the "match plate" that conforms to the contour of the
parting surface.

The gates and runners are also mounted on the match plate, so that very little hand work is
required. This results in higher productivity. This type of pattern is used for a large number of
castings.

Sweep pattern

A sweep is a section or board (wooden) of proper contour that is rotated about one edge to shape
mold cavities having shapes of rotational symmetry. This type of pattern is used when a casting
 of large size is to be produced in a short time. Large kettles of C.I. are made by sweep

Figure: Sweep pattern

Cope and drag pattern

A cope and drag pattern is a split pattern having the cope and drag portions each mounted on
separate match plates. These patterns are used when in the production of large castings; the
complete molds are too heavy and unwieldy to be handled by a single worker.

Skeleton pattern

For large castings having simple geometrical shapes, skeleton patterns are used. Just like sweep
patterns, these are simple wooden frames that outline the shape of the part to be cast and are also
used as guides by the molder in the hand shaping of the mold.

This type of pattern is also used in pit or floor molding process.

Shell pattern

Figure: Shell pattern

Follow board pattern

A follow board is not a pattern but is a device (wooden board) used for various purposes

Figure: Follow board pattern

Casting

Pouring the molten metal into the mold , and allowing it to be solidify then the desire solidify
metal object is taken out from the refractory mold by breaking the mold .The solidified metal
object is called casting.

Figure: casting product.

Types of casting

The Metal Casting or just casting process may be divided into two groups:

Hot Forming Process

Examples are Centrifugal casting, Extrusion, Forging, Full mold casting, Investment casting,
Permanent or Gravity Die casting, Plaster mold casting, Sand Casting, Shell Mold casting. The
method to be used depends upon the nature of the products to be cast.
Cold Forming Process

Examples are Squeeze casting, Pressure die casting, Gravity die casting, Burnishing, Coining,
Cold forging, Hibbing, Impact Extrusion, Peening, Sizing, Thread rolling.

Non-ferrous furnace

Figure: Non-ferrous furnace.

 SMITHY SHOP

Introduction

It’s one of the most important shop for fabricating & repairing the Ironic metal. Especially in
railway, it is necessity is untold. Different parts of a train coach are repaired & made here mostly
manual compared with automation. In smithy shop, following instruments are available
approximately:

Hammer pressing mc.

Spring Hammer press mc.
Cooper heat furnace. Gas
furnace.
Oil & water bathe.
Crank wire & rope tester.
Coal Furnace.
Steam hammer.
Hand hammers.
Clamper.

At high temperature, metal is being heated by furnaces named as Gas furnace, coal furnace
eccentric for changing the internal structure of them. Then turned them into desired shape & size
using many kinds of mc and hand tools etc. For metal hardening or tempering, here is also used
cooper-heater. Normalizing is done by water and oil bath.

Heat Treatment Processes

Annealing

Annealing involves treating steel up to a high temperature, and then cooling it very slowly to
room temperature, so that the resulting microstructure will possess high ductility and toughness, but
low hardness. Annealing is performed by heating a component to the appropriate
temperature, soaking it at that temperature, and then shutting off the furnace while the piece is in it.
Steel is annealed before being processed by cold forming, to reduce the requirements of load and
energy, and to enable the metal to undergo large strains without failure.

Tempering

Tempering involves heating steel that has been quenched and hardened for an adequate period of
time so that the metal can be equilibrated. The hardness and strength obtained depend upon the
temperature at which tempering is carried out. Higher temperatures will result into high ductility, but
low strength and hardness. Low tempering temperatures will produce low ductility, but high
strength and hardness. In practice, appropriate tempering temperatures are selected that will
produce the desired level of hardness and strength. This operation is performed on all carbon
steels that have been hardened, in order to reduce their brittleness, so that they can be used
effectively in desired applications.
Metal Quenching

Material is heated up to the suitable temperature and then quenched in water or oil to harden to full
hardness according to the kind of steels.Material is heated to the suitable temperature for
hardening, then cooled rapidly by immersing the hot part is water, oil or another suitable liquid to
transform the material to a fully hardened structure. Parts which are quenched usually must be aged,
tempered or stress relieved to achieve the proper toughness, final hardness and dimensional stability.
Alloys may be air cooled, or cooled by quenching in oil, water, or another liquid, depending upon
the amount of alloying elements in the material and final mechanical properties to be achieved.
Hardened materials are tempered to improve their dimensional stability and toughness.

The Benefits of Steel Heat Treatment

Steel parts often require some form of heat treatment to achieve an increase in hardness and
obtain maximum strength and durability. Through the many different processes of heat
treatment, the properties of steel are changed via physical and mechanical channels. As an added
benefit, heat treatment can also aid in the manufacturing process.

When we talk about the change of mechanical properties, we’re referring to the shear strength,
toughness and tensile strength of the steel. Allowing for this mechanical change in properties
enables your product to be more efficient in its daily duties and more resistant to wear and tear
during even its toughest jobs.

Heat treatment doesn’t just make steel harder. It can actually make it softer too! The softening of
steel allows for metal working operations such as deep drawing, cold forging and machining.
Thus, steel also increases its strength, making the material ductile or more flexible, while also
introducing wear-resistance characteristics, making the material tougher.

Gears, shafts, bearings and other crucial components benefit greatly from case hardening
processes such as this when we talk about not only their wear-resistance, but their overall
lifetime as well. Meaning that through these operations, fatigue-resistance is also increased
which leaves steel components working more efficiently for a longer period of time.

Extremely hard steels are often used in applications as cutting tools where highly defined edges
must be maintained—heat treatment of these steels is a critical operation to obtain the
performance and job required of them. Hard surfaces with ductile base material may be
developed by heat treatment as well. The possible applications and uses for the heat treatment of
steel seem to be endless.

More durable product.

Steel becomes tougher, stronger.
Easier to weld.
 Becomes more flexible.
Increases its wear-resistance.
Increase in overall lifetime of the part.

In Pahartoli railway smithy shop, available products are given bellow

Figure: Drawer Nut. Figure: Hanger for brake Shaft.

Figure: Safety Bracket Kinki. Figure: Tonier Bracket.

Figure: Hook Bolt. Figure: Hanger for Brake Beam.

 Figure: Pin. Figure: Safety bracket.

Figure: Bolster Spring.

Figure: Sample of different machinery produced in smithy shop.

Spring Load Testing Process:

The primary spring suspension of a bogie is an important component, essential for the derailing
safety and travelling comfort. Faster speeds and heavy loads require the use of perfect spring
components.
In spring testing process a load is applied of 7 ton and 200 kg in Lift spring. If the deflection
between two sides is less than 235mm then the spring will be rejected.

Figure: Coil Spring. Figure: Lift spring.

Profile Cutting Machine:

Profile cutting machine is usually used to cut profile of different shape and size. After cutting these
profiles can be used in different component and for safety and welding.

Figure: Profile cutting machine.

 GENERAL ELECTRIC REPAIRING (GER) SHOP

GER shop maintains and repairs all the components of electrical power source i.e. generator and
diesel power engine. In railway, the main engine which is called locomotive is only used for
running or driving the rail coaches. All other electrical power requirements are fulfilled by the
electric power generated by a diesel engine located inside the ‘power car’. This diesel engine is
coupled with a generator to produce electricity. Assembly, repairing, maintenance and
troubleshooting of these diesel-powered engines and generators located inside the power car are the
jobs of this shop. GER shop follows Periodic Overhauling Schedule.

Principle of Power Generation and Supply

Electrical power can be generated in various ways. Coupling a diesel engine with a generator is
one of them. A four-stroke diesel engine can be coupled with the shaft of a generator. As the shaft
of the generator rotates, it produces electricity. Thus, mechanical energy from diesel engine is
converted to electrical energy on a power car. This electricity is then transformed by a
transformer as per requirement and supplied to various sections which requires electric power.
Mainly this electricity is supplied to the train lightings, fans, air-conditioning systems, control
panels and other dc chargers or batteries.

Various Sections of GER Shop

Diesel Section
Armature Section
Fan Section
Fitting Section
Machining Section
Meter Section
Diesel Electric Section
Diesel Section

In diesel section, engine parts are repaired and assembled. Engines used for power generation can
be 5-cylinder, 6-cylinder or 8-cylinder four-stroke diesel engines. Various components of diesel
engines maintained in this section are: Crankshaft, cylinder liner, cylinder head, piston, piston
ring, engine block, camshaft, fuel injection pump, injection nuzzle, lubricating oil pump, cooling
nuzzle, main bearing, big end bearing, connecting rod, push rod, push tube, rocker arm etc.

Figure: Camshaft
 Figure: Nozzle

Diesel Engine Working Procedure

Diesel engines used for power productions are all V-engines. These engines operate on
conventional four-stroke cycles. Engine cylinders can be lined as 4,5,6 or 8 cylinders according to
the desired output. Fuel is injected inside the cylinder chamber with high pressure and
temperature so to gain the firing point. Timed control valves and cams are used for smooth
operation. Exhaust combustion gas is taken out and released in the environment. Water cooling
system is used for cooling the engine. The camshaft is coupled with a generator which at the same
time produces electric power. Some of the power produced by the engine is drawn by an auxiliary
coupling in order to charge the starter of the engine itself.

The specifications of different engines are:

-cylinder generator (31 KVA,175bar)

-cylinder generator (37 KVA,175bar)
-cylinder generator (53 KVA,250bar)
-cylinder generator (315 KVA,200bar)
 Figure: 6-Cylinder Diesel Power Engine Block

An 8-cylinder V-engine can operate on 1500 rpm. Hence it produced massive heat and noise.
Silencer is used to reduce the noise. Every power car contains whole two of this engine-generator
coupling, one is active and the other is reserved for emergency backup.

Armature Section

In armature section fan coil is turned manually. A rotor and a stator create a magnetic field.
Different tools and support are used for achieving this operation.

Machining Section

In machining section different parts and components of engines are machined to accurate sizes.
 Figure: Piston Figure: Cylinder Head and Lining

Fitting Section

In fitting section all the components are fitted together using various fixed supports and hand
tools. After completion of all the fittings, tests are carried out for proper functioning and then
installed inside the power car.

Figure: 5-Cylinder Engine (After Assembly)

Repair and Maintenance

The repair and maintenance done in GER shop are mainly replacement of damaged components,
adjustment of cylinder lining and piston, replacement of piston rings, armature windings,
repairing and fabrication of nozzle, chains, batteries/starters, rocker arms, bearings, pinions,
connecting rod, push rod, lubrication system and lubricating oil and overall cleaning of all the
components. Also, troubleshooting of engine control panel are carried out in GER shop.

Figure: Complete Engine and Generator Coupling Inside Power Car

 e

Figure: Engine-Generator Control Panel

Substation and Workshop Supply:

A substation is located at the Power House under the authority of GER shop. 2200KV power
cable is lined from PDB to this power house substation. From this station, power is supplied to all
the workshops, staff quarters, and nearby facilitated area located inside the workshop zone. From
this station power supply can be controlled and manipulated according to the need. Staffs work
here follow a shift-based schedule.
 Figure: Substation Control Panel and Equipment

Long before the Independence, during British Period, the ground floor and the underground of the
power house was used as a power plant. This power was supplied not only inside the
workshop, but also to nearby areas. All those installations of power plants are now damaged and
removed.

AIR CONDITIONING SHOP

Bangladesh Railway provides different types of luxurious and a/c coaches. Maintenance of the air
conditioning systems of these coaches are carried out in the Air Conditioning Shop.

Principles of Air Conditioning

Air conditioning system comprises of evaporator, compressor, condenser, receiver/drier,

expansion valve, working fluid and some other accessories. At the evaporator, heat from the
ambient air evaporates the working fluid, thus cooling the surrounding air. The compressor
circulates the refrigerant gas and compresses it increasing its pressure and making the gas hot,
similar in effect to an air pump when inflating the tire of a bicycle. At the condenser, ambient air
cools and liquefies the hot refrigerant gas, which then re-enters the refrigerant cycle. Hence, the
inside is kept cool as the heat is expelled. Expansion valve operates in order to convert the
high-pressured liquid to low pressured, cooled liquid. The temperature of the fluid inside
the evaporator is much lower than the ambient temperature.

Figure: Principle of Air Conditioning System

Air Conditioning System of Bangladesh Railway Coaches

Bangladesh Railway air-conditioned coaches carry two packaged units of air conditioning
systems on each bogie. Some coaches provide half of the conditioned space and hence require a
single unit. Capacity of each unit is 4 Ton. Each unit carries two air conditioning systems. Major
components of the system are mounted on the ceiling of the coaches. Inside of the coaches are the
targeted spaces.

Major Air Conditioning Components used in Railway Coaches

Evaporator
Blower Fan
Compressor
Condenser
Drier
Receiver
Expansion Valve
Refrigerant

Auxiliary Components used in Railway Coaches

Air Duct
Sensors
Filter
Air Mixing Chamber
Air Diffuser
Non-Return Valve

Control and Safety Equipment

Magnetic Contactor
Overload Relay
Cut-out
Pressure Gauge
pump
Images Collected From A/C Shop:

Figure: A/C Components Mounted on the Roof Figure: Compressors with Blower Fans

Figure: Compressor Figure: Blower Motors

Figure: Evaporator Figure: Condenser

Figure: Drier Figure: Pressure Gauge

Figure: Pump Figure: Refrigerant Container

Air Conditioning Procedure

The refrigerant that is used inside the system is Freon 22 or R 12(ClF2CH4). Some of the
systems also use the latest R-407C refrigerant. When the gaseous refrigerant comes into the
compressor, it is compressed and so the pressure and the temperature are increased. In the
compressor there is an inlet pipe of large diameter and another pipe of small diameter. Inlet pipe is
known as suction pipe and the other pipe is known as discharge pipe. When compressor is in
operation then the large diameter pipe becomes cold and the other becomes hot. After that the
refrigerant enters into the condenser. Here a blower fan works facilitates the heat exchanging
process. Atmospheric temperature is less than that of the refrigerant. So the refrigerant releases
heat and becomes liquid. After that it enters into an expansion valve. Sometime capillary tubes are
uses instead of expansion valve. It helps to decrease the pressure. There are two chambers near
evaporator. One of them helps to suck hot air from cabin. This hot air comes in contact with cold
refrigerant. Here a blower fan helps to return this cold air into cabin. This hot refrigerant again
enters into compressor. Hence it completes the cycle. The function of drier is to filter the
refrigerant from any moisture.

The refrigerant is pressured into compressor at 45-50psi. If it reaches in 30psi then the
compressor will be stopped. The high-pressure compressor operates in 120psi. If it reaches
180psi then the system stopped it. Two electronic devices control the limit of pressure. They are
known as high pressure cut out and low pressure cut out. Whenever the pressure of any
components deviates from the ideal limit, the overload relays shut the system down and by
sensing the temperature using the sensors, the magnetic contactor closes and opens the circuit as per
requirement.

Troubleshooting, Maintenance and Repairing

The Air Conditioning Shop maintains the regular check-up of the a/c units as per schedule. Some
special maintenance and repair are also carried out for the saloon coaches.

Maintenance services

Health of all the a/c components

Pressure check-ups
 Filter renewal

Other fittings check-ups

Troubleshooting

Malfunctioning of a/c unit

Target temperature is not achieved
No cooling effects
Damaged components
Pressure/Temperature deviations
Malfunctioning of control panel

Improper fitting of adjustable and non-adjustable components

Repairing
Any damaged components
Compressor components
Auxiliary valves
Air ducts
Air inlet/outlet chambers
Condenser unit
Diffusers
Control panel
Circuit breakups/ short circuit
Sensor units

Other fittings

Discussion

In a/c shop all the scheduled and special air-conditioned coaches are maintained and repaired.
Besides regular check-ups troubleshooting of various aroused problems are carried out. Some of
the components are renewed and some are repaired according to the requirement. Some
malfunctioning problems are solved using expertise and skills. Though the a/c units used in
Bangladesh Railway coaches are old fashioned and less effective, the Air Conditioning Shop is
still carrying its operation efficiently and providing a smooth service.
 PAINTSHOP
A colored substance which is spread over a surface and dries to leave a thin decorative or
protective coating. Paint is any liquid, liquefiable, or mastic composition that, after application to a
substrate in a thin layer, converts to a solid film. It is most commonly used to protect, color, or
provide texture to objects. Paint can be made or purchased in many colors—and in many
different types, such as watercolor, synthetic, etc. Paint is typically stored, sold, and applied as a
liquid, but most types dry into a solid.

Components of a Paint
Vehicle
Binder
Diluent or solvent or thinner
Pigment and filler
Additives
Types of Paint
Importance of Paint
Protection
Paint is used to protect all sorts of buildings and structures from the effects of water and sun.
Wooden buildings such as houses are usually painted because a coat of paint prevents water
seeping into the wood and making it rot. The paint also helps to prevent the wood from drying out
in the hot sun. Metal structures and objects of all sorts are painted to stop them from rusting. A very
large steel structure such as a bridge must have a team of painters who keep the paint in good
condition all the time.

Decoration
Paint is used to decorate all sorts of objects. Since pre-historic times, people have painted the
inside walls of their houses to make them look attractive.[2] Painting and decorating the exterior
(outside) and interior (inside) of houses is an important industry in many countries. There are
many types and colours of paint to choose from.

All sorts of other objects are painted to make them attractive. This includes furniture, toys, tools and
utensils, and street fittings. Sometimes things made of wood such as furniture are painted in
decorative patterns. In some countries, many people enjoy decorating furniture and other small
things like trays and boxes. This is one form of what is often called Folk Art. In other countries
such as Japan, painting furniture is a very skilled profession and an antique piece of decorated
furniture is very valuable. Other people enjoy the hobby of painting small objects such as model
planes or soldiers.

Art
Paintings are pictures that are done in paint. Many different types of paint are used for paintings.
They include tempera, oil paint, gouache, watercolors and acrylic paints. The paintings are
 usually done on board, canvas or paper. Many other famous paintings are done on the walls and
ceilings of buildings, such as the Sistine Chapel ceiling which was painted by Michelangelo.

Information
Paint is a very good way to give important information to people, using painted signs. Painted
signs include lane markings on the road, street signs of all sorts, advertising signs and warning
signs.

Surface preparation
Improperly prepared surfaces can result in reduced coating integrity and service life. Up to 80% of
all coatings failures can be directly attributed to inadequate surface preparation, which affects
coating adhesion. To ensure adhesion of the coating to the substrate and prolong the service life of
the coating system, select and implement the proper surface preparation. The method of surface
preparation depends on the substrate, the environment, and the expected life of the coating
system. Economics and surface contamination (including its effect on the substrate) will also
influence the selection of surface preparation methods.

The surface must be dry and in sound condition.

Remove mildew, oil, dust and dirt, loose rust, peeling paint or other contamination to ensure
good adhesion.
No exterior painting should be done immediately after a rain, during foggy weather, when rain is predicted, or when the
temperature is below 50°F - unless the coating indicates it can be used down to 35°F. Most coatings are now formulated for low
temperature use.

Paint Shop
All types of carriages (except DEMU) used in Bangladesh Railway is painted in the painting
shop. Painting of wagons is carried in the wagon shop under regulation of painting shop. All
carriage are listed to come for painting maintaining a Periodic Overhauling (POH) routine but
sometimes it may come under special schedule. The processes of painting for a carriage in a
lifetime are divided into three categories such as Lift Enamel (LE), Periodic Over Hauling
(POH), General Over Hauling (GOH). Those three categories are done separately for Inter-city,
mail and Wagon. For passenger Inter-city, LE is done once in every year. After 4 years, POH is
done once. After completing 3 POH, GOH is to be completed once in every 12 years. But for
passenger mail carriage, LE is done once in every 1.5 years. After 3 LE are done, then POH is to be
completed. Then the same procedure for GOH follows.

In previous times a carriage on average needed 12 days of work for painting. The whole
procedure of painting in a paint shop is displayed below in figure 1 (collected from Pahartoli
carriage & wagon shop, Chittagong, Bangladesh.
 Figure: working flowchart of painting for a carriage shop

The first stage is washing and scrapping. If the painting is heavily damaged and carriage is
heavily corroded then it have to be shot blasted for removal of paint, rust and dirt’s. This process is
done using the shot blasting machine under the guidance of GOH shop in a secured room. The
blasting room is isolated from environment to contain the dust particle and protect safe working
environment for others. Shot blasting is done using sand and iron particles ejecting at high
speeds from nozzle with the help of compressed air. Sand and iron particles are mixed with
compressed air through a hopper. After removal of paint and rust the carriage is coated with
anticorrosive material. Then it is transferred to carriage shop if any modification is required, next it
is transferred to paint shop for painting. If any carriage do not need sand blasting then it directly
goes to carriage shop. In these case light scrubbing is done in paint shop.

Grinding and priming is the next phase. A primer or undercoat is a preparatory coating put on
materials before painting. Priming ensures better adhesion of paint to the surface, increases paint
durability, and provides additional protection for the material being painted. Primers can usually be
tinted to a close match with the color of the finishing paint. If the finishing paint is a deep color,
tinting the primer can reduce the number of layers of finishing paint that are necessary for good
uniformity across the painted surface. Primers are also used to hide joints and seams to give a
finishing look.
In the following 3rd to 5th days the body of the carriage is coated with hard putting to remove the
roughness, dimples and sharp edges on the carriage surface. It is done in three steps as the putty
takes at least 12 hours to become hard. Every step successively reduces the dimples and
roughness. The putty is prepared in a batch weighing 104 kg in a mixer machine.

During next 6th to 8th days the body undergoes knife filling to remove the final imperfections and
produce a smooth surface. The knife filling putty is relatively liquid then hard putty as it have to fill
the small roughness. It is also done in three stages.

In 9th day rubbing and railblue color undercoating is done. In 10 th day Sutter washing and
railblue finishing is done. At 11th day lightstone undercoat and at the last day lightstone finishing and
lettering is done.

In past it took 12 working days to finish a single carriage painting. These is due to the fact that in past
the painting shop used putty that needed 12 hours to harden so it needed minimum six days for six
consecutive operations for surface finish. As painting shop uses polyester putties nowadays
which hardens in less than five minutes so these six consecutive operations can be done in less
than one day. These technology reduced the painting time of a carriage from 12 days to 4 days.

In these process 104 kg batch of lummy is prepared from 4kg packs of polyester putty with same
number of binder packs. The painting is done manually by hand without proper safety
precautions.

The convenient colored used for carriage in paint shop especially:

Golden Yellow
White Zinc
Red Oxide powder.

MILLWRIGHT SHOP

Shot Blasting Machine

Abrasive blasting is the operation of forcibly propelling a stream of abrasive material against a
surface under high pressure to smooth a rough surface, roughen a smooth surface, shape a
surface, or remove surface contaminants. A pressurized fluid, typically compressed air, or a
centrifugal wheel is used to propel the blasting material (often called the media). The first
abrasive blasting process was patented by Benjamin Chew Tilghman on 18 October 1870.

There are several variants of the process, using various media; some are highly abrasive, whereas
others are milder. The most abrasive are shot blasting (with metal shot) and sandblasting (with
sand). Moderately abrasive variants include glass bead blasting (with glass beads) and media
blasting with ground-up plastic stock or walnut shells and corncobs (Some of these substances can
cause anaphylactic shock to both operators and passersby). A mild version is soda blasting (with
baking soda). In addition, there are alternatives that are barely abrasive or nonabrasive, such as ice
blasting and dry-ice blasting.

The Working Principle of Shot Blasting Machine

The working principle of roller conveyor shot blasting machine is that adding a prescribed
number of workpieces in cleaning cabin, then closing the door and starting the machine. The
workpieces were driven by the roller and began to flip. At the same time, the projectile threw by the
shot blasting machine with high-speed, formed fan beam, uniformly blew on the workpieces
surface, so as to achieve the purpose of clean.

The thrown Projectiles and sand from the small holes on the track slip into the bottom of the
screw conveyor, through spiral feeder into the elevator, and then by hoist mentioned separator for
separation. The gas containing dust is sucked to the filter by the fan into clean gas, and then
discharged into the atmosphere. The dust through the air blew into the dust collector which is at the
bottom of the dust collector box. The used sand flowed out through the waste pipe, and the user
can reuse the waste material. The shot and sand mixture by using tube and recycled into the
chamber, then reused after the separation. The arrangement of shot blasting machine simulating by
3D dynamic simulation, all the arranged angle and position were designed and determined by
computer. On the basis of taking care of all the projectile that needed to be cleaned up to reduce the
empty throw as far as possible, so as to maximize the utilization of the shot, and reduce the wear of
the indoor protective plate.

Shotblasting Machine Maintenance

Machine Safety
All transmission parts have cover and safety warning sign.

In operation position and its opposite position, there are emergency stop buttons.

Safety interlocks for abrasive feed, blasting and maintenance area

Sealing problem, dust extraction position

We design multi layers of labyrinth sealing. Near the door, on top of cabinet, there are dust
extraction port which will suck dust away easily.

Anti-run back device of bucket elevator

In order to prevent bucket elevator run back in case of sudden stop or power failure, causing
damage to the machine, the bucket elevator has anti-run back mechanism. Housing of bucket
elevator also has protective liner.
Environment protection problem
In order to prevent tiny abrasive sucked into dust collector, we design an abrasive settlement
cabinet to settle down abrasive with size of 0.05mm. We design two steps dust remove, finally
dust concentration of exhausted air will be controlled under 85 mg.

Figure: air purifier in shot blasting machine

Automatic Screw Jack

Figure: automatic screw jack for lifting carriage

Shearing
A shear force is applied that will cut off part of a sheet. The cut off ‘blank’ becomes the
workpiece.

Shearing, also known as die cutting, is a process which cuts stock without the formation of chips or
the use of burning or melting. In strict technical terms, the process of “shearing” involves the use of
straight cutting bladesorm of sheet metal or plates, however rods can also be sheared.
Shearing-type operations include: blanking, piercing, roll slitting, and trimming

When you apply a high pressure tool through a metal plate and remove part of the metal, the
process is called shearing. Shear machining devices include punching machines, which make
small discs, and blanking machines, which produce washers and similar objects.

Direct tool ordinary machining is NOT the same as shear machining. With standard tool
machining, a single or multiple point tool can be employed to take out a piece of metal from the
metal sheet and/or block. This process required repeated pounding of the metal until the required
dimensions are achieved. With shear machining, the tool’s cutting edge removes the metal from the
plate. While this happens, maximum pressure is applied. The tool, however, only touches the metal
one time.

Both mechanical and hydraulic machines can perform shear machining. Hydraulic shears cut and
score sheet metal quickly and accurately. They work well for factories that do a lot of metal
fabrication. In addition, hydraulic shears are best if the operation requires intense pressure. They
don’t require a lot of maintenance, will operate continuously, and are fast and quiet. Hydraulic
shear machines also take up less space than mechanical shear machines while applying the same
amount of pressure. When the metal is inserted into hydraulic machines, it is secured by clamps so
it does not shift under high pressure. To ensure that the cut is smooth and even for a 90 degree cut, a
squaring arm or back gauge must be used. Minute burrs may be formed by the edge of the cut metal;
these must be removed by grinding. If you use hydraulic shears, be careful of the little marks left by
the cutting blades and holding clamps while working. You will need to remove them or otherwise
account for them

Maintenance
First, to ensure that the operation is strictly followed by the procedures, improper operation has
always been the source of the safety accidents. The operation of the violation will not only bring
security risks in production, but also cause irreversible damage to the machine equipment. The
next step is to check the condition of the lube before each boot, to make sure the oil is clean and free
of impurities.

And the cleaning of machine tools, as a commonly used machine equipment, the machine tools of
hydraulic shearing machine should be kept clean at all times. Otherwise, it will affect the work
and life of the hydraulic shearing machine. In particular, operators should check that the machine
tool itself is rusty. It is best to protect the machine tools with anti-rust paint or anti-rust oil.

The motor is the core part of the hydraulic shearing machine, which corresponds to the human
heart. And the motor bearing is the driving part of the energy, so we should pay more attention. We
need to check the lube regularly, not only add regularly, but also change regularly. And it's
important not to forget to check that part of the job. For other small details and accessories, we
need to prepare spare parts, and this is an important point, because only the normal operation of
these parts, the hydraulic shearing machine can work properly.

Figure: shearing machine

Milling machine
Milling is the cutting operation that removes metal by feeding the work against a rotating, cutter
having single or multiple cutting edges. Flat or curved surfaces of many shapes can be machined by
milling with good finish and accuracy. A milling machine may also be used for drilling, slotting,
making a circular profile and gear cutting by having suitable attachments.
Working Principle
The workpiece is holding on the worktable of the machine. The table movement controls the feed of
workpiece against the rotating cutter. The cutter is mounted on a spindle or arbor and revolves at
high speed. Except for rotation the cutter has no other motion. As the workpiece advances, the
cutter teeth remove the metal from the surface of workpiece and the desired shape is produced.
Milling Operations
Plain or slab milling
Face Milling
 Angular Milling
Straddle Milling
Form Milling
Gang Milling

Maintenance and Servicing of Milling Machines

Like any other machine, milling machines are subject to wear and tear. The physical wear is a
result of the use of the machines and of the abrasion caused by friction during use. Such wear can
be reduced by regular maintenance and servicing of the milling machine by the operator:

The degree of wear depends on:

Maintenance and servicing of the milling machine,

Properties of coolants and lubricants,
Environmental conditions (dust, temperature variations, etc.)
Operating conditions (single or multi-shift operation, volume of metal removed, proper
operation).

Table: Servicing cycle of milling machines

Compressor
An air compressor is a device that converts power (using an electric motor, diesel or gasoline
engine, etc.) into potential energy stored in pressurized air (i.e., compressed air). By one of
several methods, an air compressor forces more and more air into a storage tank, increasing the
pressure. When tank pressure reaches its engineered upper limit the air compressor shuts off. The
compressed air, then, is held in the tank until called into use.[1] The energy contained in the
compressed air can be used for a variety of applications, utilizing the kinetic energy of the air as it is
released and the tank depressurizes. When tank pressure reaches its lower limit, the air
compressor turns on again and re-pressurizes the tank.

Applications
Portable air compressor for powering tools, such as jackhammers

Air compressors have many uses, including: supplying high-pressure clean air to fill gas
cylinders, supplying moderate-pressure clean air to a submerged surface supplied diver,
supplying moderate-pressure clean air for driving some office and school building pneumatic
HVAC control system valves, supplying a large amount of moderate-pressure air to power
pneumatic tools, such as jackhammers, filling high pressure air tanks (HPA), for filling tires, and to
produce large volumes of moderate-pressure air for large-scale industrial processes (such as
oxidation for petroleum coking or cement plant bag house purge systems).

Maintenance
To ensure all compressor types run efficiently with no leaks, it is imperative to perform routine
maintenance, such as monitoring and replacing air compressor fittings. It is suggested that air
compressor owners perform daily inspections of their equipment, such as:

Checking for oil and air leaks

Checking the differential pressure in the compressed air filter
Determining whether or not the oil in the compressor should be changed
Verify safe operating temperature to avoid overheating the unit and it is used in sucking
the air

Boiler
Boiler is used in railway wagon shed for cleaning up the interior of different types of wagons.
Wagons carry a lot of items such as oil, chemical, bitumen, hazardous material etc. In wagon shop
repairment of wagons is done which include cutting, welding, heating etc. if this tanks are not
cleared properly this may make explosive vapor mixture which may explode while working. So,
this containers are cleaned before handling it to wagon shop by steam in the outer shade. It takes
on average 6-8 hours to properly cleanse a tanker. Boiler used in this facility are very old and risky.
Repairment of these boilers are done in Sayedpur carriage and wagon workshop. There is two
boilers in the workshop so when 1 is in schedule maintenance other runs.
 Figure: fire in tube boiler used in Bangladesh Railway

Maintenance

General Maintenance

A well-planned maintenance program avoids unnecessary down time or costly repairs. It also
promotes safety and aids boiler code and local inspectors. An inspection schedule listing the
procedures should be established. It is recommended that boiler room log or record be
maintained, recording daily, weekly, monthly, and yearly maintenance activities. This provides a
valuable guide and aids in obtaining boiler availability factor to determine shutdown frequency,
economies, length of service, etc.
Even though the boiler has electrical and mechanical devices that make it automatic or
semi-automatic in operation, these devices require systematic and periodic maintenance. Any
"automatic" features do not relieve the operator from responsibility, but rather free him from
certain repetitive chores, providing him with time to devote to upkeep and maintenance.

Good housekeeping helps to maintain a professional boiler room appearance. Only trained and
authorized personnel should be permitted to operate, adjust, or repair the boiler and its related
equipment. The boiler room should be kept free of all material and equipment not necessary for
operation for the boiler.

Alertness in recognizing unusual noises, improper gauge readings, leaks, signs of overheating,
etc., can make the operator aware of developing malfunction and initiate prompt corrective
action that may prevent excessive repairs or unexpected down time. All piping connections to the
system and its accessories must be maintained leak-proof because even a minor leak, if
neglected, may soon become serious. This applies especially to the water gauge glass, water
level control, piping, valve packing, and manway gaskets. If serious leaks occur shut down the
boiler immediately and gradually reduce steam pressure. Do not attempt to make repairs while the
boiler is under pressure.

Shift Maintenance

Shift maintenance should include checking the boiler water level in the gauge glass and the
boiler steam pressure on the gauge. Operate the intermittent blowdown valve to remove any
accumulated solids in the mud drum. The valves on the water column and gauge glass should be
operated to make sure these connections are clear. Monitor water chemistry to adjust the
chemical feed treatment and continuous blowdown as required, to remain within water treatment
guidelines established by the Owner's water treatment consultant.

Daily Maintenance

Daily Maintenance should include a check of the burner operation, including fuel pressure,
atomizing air or steam pressure, visual appearance, etc. Clean the observation ports during
periods of low fire or shutdown. Test the boiler level alarms and low water cutoff. Maintain a daily
schedule of soot blowing.

Monthly Maintenance

Check the condition of the refractory for significant damage or cracking. Patch and repair the
refractory as required. Frequent wash coating of refractory surfaces is recommended. Use high
temperature bonding, air-dry type mortar diluted with water, to the consistency of light cream, for
this purpose. This will seal small cracks and prolong the life of the refractory. Any large cracks
should be cleaned out and filled with mortar.

Follow the recommendations of you authorized inspector pertaining to safety valve inspection and
testing. The frequency of testing, either by the use of the lifting lever or by raising the steam
pressure, should be based on the recommendation of your authorized inspector. Test the boiler
safety valves in accordance with the manufacturer's instructions to be absolutely sure that the
valves have not corroded shut. Failure of the relief valves in an overpressure situation is
DISASTROUS!

Annual Maintenance

Have the unit inspected and checked by a service representative from the manufacturer, if
possible.

Clean both the heating and heated sides of the boiler. Remove all manway and handhole covers.
Open all bottom blowdown and drain valves. Hose the inside of the boiler with clean water under
high pressure. Use a hand scraper to remove accumulated sludge and scale. Start near the top and
work toward the bottom. After cleaning tube exteriors, inspect the tube surfaces for signs of
overheating, such as bulging, blackened surfaces in the tubes, etc.

Specific local conditions determine the use of "wet" or "dry" storage during shutdown periods. If
you are unsure of which procedure to follow, contact the Owner's water treatment consultant or
your local insurance company.

Replacement of Flange, Manway, and Handhole Gaskets

1. Clean metal surfaces where cover plate bears against shell plate or ring.

2. Always use new gaskets. Apply graphite paste to gasket to prevent sticking and assure
tightness.

3. Use care in centering cover plate and gasket in shell opening. Draw bolts up firmly. Yokes are
designed for the positioning and holding of the covers only. Gasket sealing is accomplished by the
application of internal pressure.

4. Spare gaskets should be maintained in your inventory to minimize your downtime.

Annual Inspection

Insurance regulations or local laws will require a periodic inspection of the pressure vessel by an
Authorized Inspector. Sufficient notice is generally given to permit removal of the boiler from
service and preparation for inspection. This major inspection can often be used to accomplish
maintenance, replacements, or repairs that cannot easily be done at other times. This also serves as
a good basis for establishing a schedule for annual, monthly, or periodic maintenance
programs.

While this inspection pertains primarily to the waterside and fireside surfaces of the pressure
vessel, it provides the operator an excellent opportunity for detailed inspection and check of all
components of the boiler including piping, valves, pumps, gaskets , refractory, etc.
Comprehensive cleaning, spot painting or re-painting and the replacement of expendable items
should be planned for and taken care of during this time. Any major repairs or replacements that
may be required should also, if possible, be coordinated with this period of boiler shutdown.
Replacement spare parts, if not on hand, should be ordered sufficiently prior to this shutdown.

Have available information on the boiler design, dimensions, generating capacity, operating
pressure, time in service, defects found previously, and any repairs or modifications. Also have
available for reference records of previous inspections. Be prepared to perform any testing
required by the inspector including hydrostatic testing of the equipment.
 ACKNOWLEDGEMENT

The authors gratefully acknowledges the support of works manager, carriage & wagon repair
workshop, Pahartali, Bangladesh Railway and Department of Mechanical Engineering,
Chittagong University of Engineering & Technology.

DISCUSSION

Of all this shop there has a common problem. That is new recruitment for the blank post. Again
there has some block post. There is no competition to develop worker's skill. The budge fixed for any
shop is not sufficient. Bangladesh railway is an asset of Bangladesh. New coach production
technology is in the workshop. If administration takes necessary steps, it is possible to make a new
coach in future. There is no residential area for trainee. So administration can arrange that. After all
everybody helps us a lot for giving us training. We are grateful to Bangladesh railway carriage and
wagon workshop, pahartoli, chittagong.