INTERNSHIP REPORT

BEML LIMITED

Bangalore complex: C V Raman Nagar

Bengaluru ,Karnataka -560075

Submitted by:

Sanjay S Gowda (1BI16ME119)

Sayandh S P (1BI16ME122)

Shammith P (1BI16ME125)

Vijeth S (1BI16ME157)

Branch: Mechanical Engineering

College: BANGALORE INSTITUTE OF TECHNOLOGY

K R Road,v.v.Pura, Bangalore-560004

JULY – AUGUST 2019

 ACKNOWLEDGEMENT
I would like to express my heartfelt gratitude to BEML Limited (Bharat Earth
Movers Limited formerly Bharat Earth Movers Limited), Bangalore Complex for
providing me with the opportunity to complete this internship program at this
organization.
This internship is a result of the valuable insights, facts and experiences I had
during my program at BEML. The experience earned was highly informative and
educative and lead me to understand the realms of design, concept of a product on
paper and transforming the same into an actual product. I would like to express my
sincere appreciation to the Deputy General Manager-Marketing (Rail and Metro)
for his valuable guidance, support and encouragement to complete this program.
In addition, I have been fortunate enough to receive whole-hearted co-operation,
able supervision, valuable and timely guidance extended by the HR (Human
Resources) department, Training Centre and executive & supervisory staff of
various departments and personnel of every production hanger in BEML.
Also, I want to express my sincere gratitude for the whole hearted support given by
my college National Institute of Technology Karnataka (NITK) for facilitating this
program.
Last but not the least, I would like to thank my parents for their encouragement and
support without which this would not have been successfully completed.

Sanjay S Gowda (1BI16ME119)

Sayandh S P (1BI16ME122)

Shammith P (1BI16ME125)
Vijeth S (1BI16ME157)
 CONTENTS
CHAPTER TOPIC PAGE NO.
1 About the company 1-8
2 Products 9 - 11
3 Work flow diagram 12
4 Production 13 -16
department
5 Underframe 17 – 21
department
6 Bogie section 29 – 33
7 Machining section 34 – 36
8 Test track 37 – 38
9 Quality department 38 – 39
10 Metrology 40 – 41
department
11 Product design 41 – 42
department
12 Planning 42
department
13 conclusion 43
 CHAPTER 1
ABOUT THE COMPANY
BEML Ltd is the leading manufacturer of heavy earth moving equipment in Asia and an
Indian Public Sector Company under the Ministry of Defence Govt. of India. It is a Mini Ratna
Category - I Public Sector Enterprise operating in three distinct business verticals namely Mining
& Construction Defence & Aerospace and Rail & Metro. The company's International Business
Division exports equipment and spares manufactured and also provide services by all the three
verticals. The major markets for exports are Middle East countries African countries and South
East Asian countries. As part of the globalization strategy the company's products have been
exported to about 68 countries.
The company has four manufacturing complexes located at Bengaluru Kolar Gold Fields
(KGF) Mysuru and Palakkad and a subsidiary steel foundry functioning in Tarikere
Chikkamagaluru district. The company's Mining & Construction division offers range of mining
machinery for both opencast and underground mines. The Rail & Metro business vertical
supplies integral rail coaches overhead electric inspection cars and postal vans to Indian
Railways. Defense Division manufactures variants of Tatra vehicle for all terrain operations
including bridge layer field artillery tractor medium and heavy recovery vehicle.In addition to
the above Technology Division of the company provides end-to-end technology solutions in
Auto Aero Defence and Rail & Metro related areas. The Trading Division deals with non-
company products and commodities such as iron ore coal and steel billets for both captive in-
house requirements. International Business Division deals with export activities.

1.1 History

BEML incorporated in May 1964, and commenced operations on 1 January 1965 with a
Tractor project that was transferred from the Gun and Shell Factory of the Ordnance Factory
Board. [2] It was wholly owned and operated by India's Ministry of Defence until 1992, when the
government divested 25% of its holdings in the company. BEML is Asia's second-largest
manufacturer of earth moving equipment, and it controls 70% of India's market in that sector. Its
stock trades on the National Stock Exchange of India under the symbol "BEML", and on

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the Bombay Stock Exchange under the code "500048". The company went for Follow on Public
offer (FPO) and fixed the price band for its FPO between Rs. 1,020 and Rs. 1,090.

1.2 BEML-an overview

BEML Ltd, a public sector undertaking with the name Bharat Earth Movers Ltd under
the administrative control of Department of Defence Production and Supplies Ministry of
Defence. The company commenced operations at Bangalore with the transfer of railway coach
manufacturing facilities from Hindustan Aeronautics Ltd with land building plant and machinery
for a consideration of Rs 600 lakh. In the very first year of starting operations they started
manufacturing wide range of wheeled mining and construction equipment under technical
collaboration with a US company.During the year 1967-68 the company commissioned Heavy
Earthmoving Equipment Division at Kolar Gold Fields. In the year 1979 they entered into a
collaboration agreement with Komatsu Limited Japan for technical know-how in a wide range of
mining and construction equipment such as bulldozers. In the year 1985 the company established
the Dump Truck Division at Mysore. Also Vignyan Industries Ltd became a subsidiary of the
company during the year by transfer of shares constituting over 75% from the GoK.In the year
1987 the company set up an exclusive Hydraulics and Powerline Division and a full-fledged
R&D centre in the Kolar Gold Field (KGF) facility. In the year 1991 they set up their engine
division at Mysore for manufacture of heavy duty diesel engines. In the year 1992 the
Government of India divested the equity shares in the company and in February 21 1992 the
company was converted into a public limited company. Also the company was recognized as an
Export House with Star Exporter status during the year.In the year 1994 the company shares
were listed at the Stock Exchanges at Bangalore Mumbai Kolkata Delhi and Chennai. Also the
company launched the Mammoth equipment 'walking dragline'. In the year 1996 the company
entered a major counter trade agreement with Syria executed against import of rock phosphate.
In the year 1998 the company bagged orders against World Bank tenders valued at Rs. 70000
lakh for equipment supply to CIL projects. During the year 2003-04 the company entered the
Metro Railway business with the manufacture and supply of hi-tech stainless steel metro coaches
to the Delhi Metro Rail Corporation. In the year 2004 they acquired over 1100 acres of land and
2 workshops on lease basis from the now-defunct public sector undertaking Bharat Gold Mines

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Ltd in Kolar Gold Fields for supporting their expanding production activities in the defence and
railway sectors. Also they formally launched 7 T Class Excavator - BE71 and Backhoe loader -
BL 9H. During the year 2005-06 the company introduced the R&D's innovative product Load
Haul Dumper (LHD) - BL15 and exhibited in the IMME - Kolkata. A four-cylinder indigenous
engine B4D105 was successfully built tested evaluated and fitted on one of the earthmoving
equipment for user trials. Also the in-house developed 20T class Excavator BE200 has
successfully completed user trials and released for production.From April 1 2006 the company
underwent organizational restructuring to improve their competitiveness in the global market.
Consequent to this the company's operations was divided into three business groups namely
Mining & Construction Defence and Railway & Metro Business. In April 12 2006 the company
diversified into new business areas by opening two new divisions namely Technology Division
and Trading Division. In August 29 2006 the company was conferred 'Mini Ratna - Category 1'
status by the Ministry of Defence. In September 2006 the company signed an MoU with CCC
(Compagnie Comercio E Construcoes) and established a joint venture company for
manufacturing and supplying of rail wagons & bogies mining & construction equipment and
spares. In December 2006 the company entered into an agreement with US based Terex Mining
to manufacture sell and service and to provide support for certain mining haul trucks of Terex
design. In February 2007 Taneja Aerospace & Aviation Ltd signed an MoU with the company at
Aero India 2007 in order to explore the aeronautical offset opportunities in the defence and
civilian sectors and also the development opportunities in the domestic market. During the year
2007-08 the company's R&D Centre developed Pipe Layer BP70X with unique features like
modular planetary winches mounted on one side for improved visibility rugged boom pilot
operated hydraulic system. Also the company launched the R&D Centre developed equipments
namely Hydraulic Excavator BE700 and Transmission for BH35-2. In April 18 2007 the
company formed a joint venture company namely BEML Midwest Ltd at Hyderabad. The joint
venture is a professionally well knit company with the company having 45% share Midwest
Granite Pvt Ltd and P T Sumber Mitra Jaya of Indonesia as partners with 55% share. The name
of the company was changed from Bharat Earth Movers Ltd to BEML Ltd with effect from
October 5 2007.In October 2007 the company launched marketing office cum warehouse at
Malaysia in the name of BEML (Malaysia) Sdn Bhd (787108-A) at Johor Bharu. Also they
secured an order from Delhi Metro Rail Corporation (DMRC) for manufacture and supply of 156

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numbers state of the art standard gauge stainless steel metro cars towards second phase of
operation worth Rs 1144 crore.During the year 2008-09 the company's R&D developed BE300
with Rexroth Hydraulics BL200 Re-engineered version WS70 High Capacity water Sprinkler
BA28 Air craft Towing Tractor Transmission and Torque Converter for BH35-2. In May 2008
the company entered into an MoU with Steel Authority of India Ltd in which SAIL will purchase
a total number of 261mining equipment over a period of next three years. Also the company
signed a long term agreement for 12 years with Coal India Ltd for joint production of Off the
Road (OTR) to meet the requirement for production by the company and after sale requirement
by Coal India Ltd. During the year 2009-10 the company's R&D developed Snow cutter 125 Ton
Excavator upgraded version of BD 65 with joystick controls for work attachment Arm chair
steering control and hexagon ROPs cabin transmission and torque converter for BH 50M. In
April 2009 the company established their assembly unit Beml Brasil Industrial Ltda at Rio De
Janeiro Brazil. In August 2009 the company launched their local company namely PT BEML
Indonesia at Jakarta in Indonesia. Also they inaugurated the Indonesian Marketing cum Spares
Depot and Service Centre at Balikapapan Indonesia.In October 8 2009 the company received
Construction World Award 2009 for the fastest growing construction equipment company by
Union Minister for Roads Transport and Highways at Mumbai. In October 15 2009 the company
received SCOPE Award from Hon'ble Prime Minister for Excellence and Outstanding
Contribution to the Public Sector Management Medium PSE Category for the year 2006-07. In
January 16 2010 the company received the Golden Peacock Award (Innovative management
category) at Bangalore.In March 2010 the company bagged an order worth Rs 632 crore from the
Ministry of Defence for supply of BEML Tatra variants. In May 16 2010 the company
inaugurated the Greenfield Project at Kanjikode Palakkad and the Unit became operational
rolling out Defence products and Rail parts. In June 2010 the company signed an MoU with
Karnataka Government for establishing another manufacturing complex in Bangalore. In
February 7 2011 the BEML Aerospace Manufacturing Division at Mysore with Horizontal
Machining Centre facilities was inaugurated at their Mysore Complex. This division will
manufacture Gears for helicopters Jigs for aircraft structures Machining of aerospace
components Fabrication of structural sub-assemblies for Su-30 aircraft and Variety of Ground
Support and Ground Handling equipment. Further this new Division will undertake manufacture
of complex gears and gear boxes for helicopters and aero engines landing gears of aircraft

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fabrication of minor and major structural assemblies and upgrades of aircraft and helicopters.
During the financial year ended 31 March 2014 BEML's international presence increased to 63
countries with exports to Taiwan and Gabon during the year. During 2013-14 BEML procured
goods and services to the extent of Rs. 98.58 crores from Micro and Small Enterprises (MSEs)
which constituted 6.67% of the total procurement value of Rs. 1476.86 crore.During the year
under review BEML's Mining & Construction business vertical designed developed and supplied
Motor Grader BG 605I and Hydraulic Excavator BE 220G. The business vertical designed
developed and rolled out 100 Ton Dumper with Electric transmission MTU engine and rear axle
with ABS ASR and integral parking brake. It also rolled out BD 155 Dozer with electronic
engine Electronic Transmission joystick controls Integral Hexagonal ROPS / FOPS cabin and
improved aesthetics.During the year under review BEML's Defence business vertical procured
order for manufacturing aggregates for Akash Missile from BDL. The business vertical also
bagged an order for design and manufacturing of 2 nos. of ARRV from CVRDE. During the year
under review the company's Rail & Metro business vertical bagged a new order for manufacture
and supply of 92 Standard Gauge Metro Cars for the prestigious Phase III RS-9 Project of Delhi
Metro Rail Corporation Limited (DMRCL). The first trial run of Jaipur Metro Rail Car
manufactured and supplied by BEML was flagged off by Chief Minister of Rajasthan during the
year.During the financial year ended 31 March 2016 BEML achieved all time high Sales (net of
consortium) of Rs 3287.44 crores. BEML's international presence increased to 66 countries with
exports to Djibouti and Congo during the year. During the year under review the company's
Mining & Construction business vertical designed developed and rolled out Compact Loader
cum Excavator BL120H for construction sector. It also designed developed and rolled out 117HP
Dozer BD50 with Hydrostatic Transmission. This business vertical supplied the biggest Made-
in-India Electrical Excavator BE1800E to the market. During the year under review BEML
opened its District Office at Leh for extending after sales support to its Mining & Construction
equipment deployed through DGBR and E-In-C.During the year under review the company's
Defence business vertical designed and developed SMERCH 8x8 & 10x10 High Mobility
Vehicle with additional steerable rear wheel. The business vertical bagged order for
manufacturing and supplying of 2 nos. ofT-72 Trawl Hull. It also bagged order for
manufacturing and supplying Surface Mines Clearing System. The Defence business vertical got
Bulk Production Clearance for manufacturing and supplying aggregates for section IV & V of

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Akash Missile to M/s. Bharat Dynamics Limited. During the year under review the Defence
business vertical completed designing part of Arjun Repair & Recovery Vehicle (ARRV) in
association with CVRDE and Army.During the year under review BEML's Rail & Metro
business vertical bagged a new order for manufacture and supply of 96 Cars for RS-13 Project of
Delhi Metro Rail Corporation Limited (DMRCL). It also bagged order for manufacture and
supply of 84 Cars for Kolkata East-West Metro Line Project of Kolkata Metro Rail Corporation
Limited (KMRCL). During the year under review the business vertical designed developed and
supplied Catenary Maintenance Vehicle for Navi Mumbai Metro Corporation.During the year
under review about 70% of the company's total requirements of materials and services were
sourced through e-procurement platform on ERP system. During 2015-16 BEML placed orders
for goods and services to the extent of Rs.188.58 crores from Micro and Small Enterprises
(MSEs) which constituted 12.37% of the total procurement value of Rs.1524.45 crores.The
Ministry of Defence (MoD) vide its letter dated 1 December 2016 communicated that Cabinet
Committee on Economic Affairs (CCEA) had accorded in-principle approval for strategic
disinvestment of BEML. Department of Investment and Public Asset Management (DIPAM)
vide its O.M. dated 19 December 2016 communicated that an Inter-Ministerial Group (IMG) had
been constituted by the competent authority for the purpose of appointing intermediaries such as
Asset Valuer (AV) Transaction Advisor (TA) and Legal Advisor (LA) for the strategic
disinvestment of 26% equity in the company out of Government of India shareholding of
54.03%. After confirmation BEML vide letter dated 06 January 2017 intimated NSE and BSE
about the `inprinciple' approval of CCEA and also posted on the web-site of the company in
terms of Regulation 30 of SEBI (Listing Obligations & Disclosure Requirements) Regulations
2015. As per the terms MoD has appointed M/s RBSA Valuation Advisers LLP Ahmadabad as
Asset Valuer and DIPAM has appointed M/s. SBI Capital Markets Limited as TA and M/s
Crawford Bayley as LA respectively. Preliminary Information Memorandum (PIM) and
Expression of Interest (EoI) has been submitted by TA.BEML recorded Profit before Tax of Rs
98.29 crores in 2016-17 as against Profit before Tax of Rs 77.92 crores recorded in the previous
financial year which is the highest ever in the last five years. On the exports front the
international presence of BEML increased to 67 countries with the entry to Benin during the
year. During the year about 70% of the company's total requirements of materials and services
were sourced through e-procurement platform on ERP system. During 2016-17 BEML placed

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orders for goods and services to the extent of Rs 303.93 crores from Micro and Small Enterprises
(MSEs) which constituted 20.42% of the total procurement value of Rs1488.14 crores and
32.93% of indigenous procurement of Rs 922.90 crores. During the year ended 31 March 2017
the company's R&D Centre designed developed and launched upgraded version of 100T Dumper
(BH 100-1) to suit customer requirements in addition to successful up-gradation of other existing
products of the company.During the year under review BEML's Mining & Construction business
vertical signed a Memorandum of Understanding (MoU) with Dredging Corporation of India Ltd
for indigenous design development and manufacture of spares for dredgers. During the year
under review the company's Defence business vertical successfully indigenised Power Take Off
Assembly for 8x8 High Mobility Vehicle. During the year under review the company's Rail &
Metro business vertical bagged a new order for manufacture and supply of 150 Cars for
Bangalore Metro Rail Corporation Limited (BMRCL). During the year under review BEML
opened its District Office at Vijayawada Andhra Pradesh for extending all sales support for its all
Business Vertical.During the financial year ended 31 March 2018 BEML achieved all time high
Revenue from Operations of Rs 3305 crores as against Rs2835 crores in the previous year
registering growth of 16.61% compared to previous year Revenue from Operations. The increase
in sales is mainly on account of increase in the turnover of Rail & Metro Business due to
increase in sale of metro cars to Delhi Metro Rail Corporation under RS-10 RS-13 and Kolkata
Metro Rail Corporation projects. The Profit before Tax was about Rs 164 crores as against Profit
before Tax of Rs 98 crores recorded in the previous financial year which is the highest ever in
the last six years. During the year under review under `Make in India' concept launched by the
Government of India BEML designed and developed products such as 180T (BE1800D) Diesel
Excavator 850HP BD475-1Bull Dozer under Mining & Construction Segment Arjun Armed
Repair & Recovery Vehicle Truck Mounted Crane Medium Bullet Proof Vehicle High Mobility
Vehicle for 155mm caliber Mounted Gun System under Defence Segment and Metro Cars for
Kolkata Metro Rail Corporation and Intermediate Metro Cars for Bangalore Metro Rail
Corporation Limited under Rail & Metro Segment. The company's Mining & Construction
business vertical launched 5.4 ton 3.1 cum bucket Wheel Loader BL30-1 during Excon
Exhibition 2017. During the year under review the company's Defence business vertical opened
spare parts and warehouse office at Pune Maharashtra. During the year under review the
company's Rail & Metro business vertical established the 3rd line Metro Manufacturing facilities

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at Bengaluru Complex to increase the production capacity of Metro cars. During the year
BEML's R&D Centre designed developed and launched upgraded version of various products
under Mining & Construction Rail & Metro and Defence segments of the company. The
financial year 2017-18 was a milestone year for BEML as major improvements and initiatives
were implemented in the HR areas related to leveraging IT for HR Succession Planning for
critical senior positions process reengineering and optimization of human capital Leadership
development programmes through training abroad and also at IIM's / XLRI etc. BEML entered
into a Consortium Agreement with M/s. Coal India Limited (CIL) and M/s. Damodar Valley
Corporation (DVC) on 8 June 2010 for acquiring specified assets of M/s. Mining and Allied
Machinery Corporation Limited (MAMC) (under liquidation). The agreement inter-alia provided
for formation of a Joint Venture company (JV) with a shareholding pattern of 48:26:26 among
BEML CIL and DVC respectively. Considering that further investment/expenditure on this
project would be an additional burden on the company the Board of Directors of BEML
suggested taking up the matter with Interim Board of Management of Consortium of BEML CIL
and DVC for exit option rather than pursing with M/s. SBI Caps for preparing the Financial
viability & Business Plan report of the proposed JV. Hence it was proposed to take up with
Interim Board of Management of Consortium of BEML CIL and DVC for exploring the
possibility of selling the assets of erstwhile MAMC purchased through Court auction either by
Consortium as a whole or the share of BEML to a prospective buyer if any. Further to the
discussion held on 25 April 2018 among the members of MAMC Consortium a draft Deed of
Conveyance has been proposed to submit to the Official liquidator of Calcutta High Court for
further action.

1.3 Objectives of Beml

 Providing training for upgrading skills and competency

 Giving the local community easy access to its hospital and healthcare facilities like family
welfare, immunization
 Enabling the rural children to realize their dream of education free of cost by maximizing
the opportunities available in its schools
 Providing the local population free access to its sports facilities

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  Enhancing availability of safe drinking water.
 Enhancing connectivity through road infrastructure.
 Emphasizing on clean and eco-friendly technologies with zero environmental impact.

1.4 Vision

Become a market leader, as a diversified Company, supplying quality products and services to
sectors such as Mining & Construction, Rail & Metro, Defence & Aerospace and to emerge as a
prominent international player.

1.5 Mission

Improve competitiveness through collaboration, strategic alliances & joint ventures, to sustain
and enhance market share in product groups BEML operates.Grow profitably by aggressively
pursuing business & market opportunities in domestic and international markets by pursuing at
least 10% of Sales in exports. Adoption of state-of-the-art technologies and bring in new
products through ToT and in-house R&D efforts by achieving the objectives of the 3 year R&D
Roll on plan.Continue to diversify and grow to address new products and markets with turnover
from in-house R&D developed products at around 60%.

Attract and retain people in a rewarding and inspiring environment by fostering creativity and
innovation with attrition levels less than 5%.Offer technology and cost effective total solutions
for enhanced Customer Satisfaction.

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 CHAPTER 2

PRODUCTS

BEML Bangalore is involved in the manufacture of rail products.

 Broad gauge metro car.(25KV ac)

 Standard gauge metrocar (25KV ac)

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  Standard gauge metro car (750v dc)

Following are the broad specifications of the car:

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 2.1 Other Railway Products:

BEML since its inception has been supporting Indian Railways by manufacturing and
supplying equipment’s such as:
 Second Class Passenger Coaches (Sleeper).
 DC EMU’s.
 AC EMU’s.
 Stainless Steel EMU’s.
 Rail Busses.
 8-Wheel & 4-Wheel Overhead Electric Inspection Cars (Catenary eqpt.).
 Treasury vans.
 Spoil Disposal Units.
 Track Laying Equipment.
 Military Rail Coaches and Wagons for Defence Requirements.
 Utility Track Vehicles (UTV).

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 CHAPTER 3
Work flow diagram

Order from
customer

Marketing

R &D

Product design

Planning

Purchase

Progress

Inspection

Production/
manufacturing

Finished goods

Inspection

Shipping/delivery
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 CHAPTER 4
PRODUCTION DEPARTMENT
CAR BODY SHOP- Each metro car consist of six modules.

 Under frame

 Side wall LH

 Side wall RH

 End wall

 Cab

 Roof

Each of the above mentioned components start their journey from stainless steel parts that are
sub-contracted to other companies. The side wall and the roof are fabricated in the car body
shop.

According to the drawings both the side wall and roof are fabricated using robotic spot welding
machines. The weld points are also specified in the drawing. The fixtures are welded using TIG
(tungsten inert gas welding).

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LAY OUT OF METAL FABRICATION SHOP

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LAY OUT OF CAR BODY SHOP

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 CHAPTER 5

UNDER FRAME SECTION

This section forms an integral part of the overall assembly as it has to support the weight of the
car. This section manufactures underframes for Indian railways, suburban trains and metro. For
the metro stainless steel is used which is in contrary to the mild steel used for Indian railways
and the sub urban trains. Basic process that are involved are MIG, spot and seam welding.

SEAM WELDING

The three sheets are placed on a jig with the seam welding machine running along the side of the
jig. The X in the figure indicate the initial tact weld. Once this is done a complete weld as
indicated by the line is done.

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The seam welding machine consist of a roller which has high electrical resistance.it also has a
supply of cooling water which helps in solidifying the weld immediately.

Principle-when the power supply is switched on due to the high resistance of the roller wheel,
heat is generated. When this roller is touched to the SS sheets they melt and solidify joining the
two sheets.

The underframe consists of two end blocks and a mid-block. All these are made from basic
components and welded either using spot or MIG welding’s as per drawings. The body bolster
and the center sill are made of mild steel and separately made before welding to the underframe.

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KEYSTONE WELDING MACHINE

-the weld points are initially fed to the machine. The machine stores them as (x,y,z) co-ordinates.
For each program of welds there are 34 points (17 done by each robot).there is a pneumatically
activated holding device which keeps the surface of the sheet on the datum. The operator uses
the joystick to move the robots. The robots have their own NC codes which the computer
processes.

END UNDER FRAME

The end under frame consists of the following components

1. Body bolster.

2. Center sill.

3. Rear assembly of center sill.

4. Support beams.

5. Anti-climbers.

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The sub-assemblies of the body bolster and center sill are welded using MIG welding. Initially
tact weld is performed then continuous weld is done. The attaching surface of the body bolster is
machined by a face mill in the machining section. All the components are then welded using
MIG welding. Vertical welding is also performed by using a jig that can rotate 360 degrees.
After vertical welding the given assembly is turned 180 degrees and welding on the underside is
done. Then the end under frame is grinded and buffed. After this tests are conducted in order to
check for any defects present. This is then inspected by the customer who gives the clearance to
proceed to the underframe shop.

360 degree under frame welding jig

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LAY OUT OF END UNDER FRAME SECTION

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FURNISHING SECTION (OUTFITTING DEPARTMENT)

Once the car rolls out from the car body shop its outer structure is complete .This serves as the
input to this section. The car body then spends the next thirty days in this section. The following
are added to the car body shell in this section.

 Floor boards over which linoleum covers are put.

 Glass wool insulation is done. Since the metro car is an air-conditioned car it is imperative to
carry out the insulation properly.Infact only after the customer is satisfied with this does he clear
the car to move further.

 Window glasses are installed using seals.

 Roof and under frame cable ducts are added.

 Doors and their opening and closing systems are installed.

 Interior panels are installed throughout the car.

 Plastic seats are also installed.

 Piping for the braking is installed as per drawings.

 Electrical units are installed.

 Compressors, battery boxes, invertor units are installed.

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PIPING AND BRAKING

The air braking system is used in the metro car.it is an electro-pneumatic controlled system. The
main compressor unit is located in the trailer car. Power required to run the main compressor is
taped from the electrical grid using the pantograph. There is also an auxiliary compressor unit for
lifting and dropping of the pantograph. The voltage required for the compressor is stepped down
using a step down transformer. The metro train system comes equipped with three brakes

1. Service brake

2. Emergency brake

3. Parking brake

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The main parts of the braking system are

COMPRESSOR

The pump which draws air from atmosphere and compresses it for use on the train. Its principal
use is for the air brake system, although compressed air has a number of other uses on trains.

MAIN RESEVOIR

Storage tank for compressed air for braking and other pneumatic systems.

DRIVERS BRAKE VALVE

The means by which the driver controls the brake. The brake valve will have (at least) the
following positions: "Release", "Running", "Lap" and "Application" and "Emergency". There
may also be a "Shut Down" position, which locks the valve out of use. The "Release" position
connects the main reservoir to the brake pipe. This raises the air pressure in the brake pipe as
quickly as possible to get a rapid release after the driver gets the signal to start the train. In the
"Running" position, the feed valve is selected. This allows a slow feed to be maintained into the
brake pipe to counteract any small leaks or losses in the brake pipe, connections and hoses.
"Lap" is used to shut off the connection between the main reservoir and the brake pipe and to
close off the connection to atmosphere after a brake application has been made. It can only be
used to provide a partial application. A partial release is not possible with the common forms of
air brake. "Application" closes off the connection from the main reservoir and opens the brake
pipe to atmosphere. The brake pipe pressure is reduced as air escapes. The driver (and any
observer in the know) can often hear the air escaping. Most driver's brake valves were fitted with
an "Emergency" position. Its operation is the same as the "Application" position, except that the
opening to atmosphere is larger to give a quicker application.

FEED VALVE

To ensure that brake pipe pressure remains at the required level, a feed valve is connected
between the main reservoir and the brake pipe when the "Running" position is selected. This
valve is set to a specific operating pressure.

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EQUALISING RESEVOIR

This is a small pilot reservoir used to help the driver select the right pressure in the brake pipe
when making an application. When an application is made, moving the brake valve handle to the
application position does not discharge the brake pipe directly, it lets air out of the equalising
reservoir. The equalising reservoir is connected to a relay valve which detects the drop in
pressure and automatically let’s air escape from the brake pipe until the pressure in the pipe is
the same as that in the equalising reservoir. The equalising reservoir overcomes the difficulties
which can result from a long brake pipe. A long pipe will mean that small changes in pressure
selected by the driver to get a low rate of braking will not be seen on his gauge until the change
in pressure has stabilized along the whole train. The equalizing reservoir and associated relay
valve allows the driver to select a brake pipe pressure without having to wait for the actual
pressure to settle down along a long brake pipe before he gets an accurate reading.

Brake Pipe

The pipe running the length of the train, which transmits the variations in pressure required to
control the brake on each vehicle. It is connected between vehicles by flexible hoses, which can
be uncoupled to allow vehicles to be separated. The use of the air system makes the brake "fail
safe", i.e. loss of air in the brake pipe will cause the brake to apply. Brake pipe pressure loss can
be through a number of causes as follows:

 A controlled reduction of pressure by the driver

 A rapid reduction by the driver using the emergency position on his brake valve

 A rapid reduction by the conductor who has an emergency valve at his position

 A rapid reduction by passengers using an emergency system to open a valve

 A rapid reduction through a burst pipe or hose

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 A rapid reduction when the hoses part as a result of the train becoming parted or derailed.

ANGLE COCK

At the ends of each vehicle, "angle cocks" are provided to allow the ends of the brake pipe hoses
to be sealed when the vehicle is uncoupled. The cocks prevent the air being lost from the brake
pipe.

COUPLED HOSES

The brake pipe is carried between adjacent vehicles through flexible hoses. The hoses can be
sealed at the outer ends of the train by closing the angle cocks.

BRAKE CYLINDER

Each vehicle has at least one brake cylinder. Sometimes two or more are provided. The
movement of the piston contained inside the cylinder operates the brakes through links called
"rigging". The rigging applies the blocks to the wheels. Some modern systems use disc brakes.
The piston inside the brake cylinder moves in accordance with the change in air pressure in the
cylinder.

AUXILIARY RESEVOIR

The operation of the air brake on each vehicle relies on the difference in pressure between one
side of the triple valve piston and the other. In order to ensure there is always a source of air
available to operate the brake, an "auxiliary reservoir" is connected to one side of the piston by
way of the triple valve. The flow of air into and out of the auxiliary reservoir is controlled by the
triple valve.

BRAKE BLOCK

This is the friction material which is pressed against the surface of the wheel tread by the upward
movement of the brake cylinder piston. Often made of cast iron or some composition material,
brake blocks are the main source of wear in the brake system and require regular inspection to

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see that they are changed when required. Many modern braking systems use air operated disc
brakes. These operate to the same principles as those used on road vehicles.

BRAKE RIGGING

This is the system by which the movement of the brake cylinder piston transmits pressure to the
brake blocks on each wheel. Rigging can often be complex, especially under a passenger car
with two blocks to each wheel, making a total of sixteen. Rigging requires careful adjustment to
ensure all the blocks operated from one cylinder provide an even rate of application to each
wheel. If you change one block, you have to check and adjust all the blocks on that axle.

TRIPLE VALVE

The operation of the brake on each vehicle is controlled by the "triple valve", so called because it
originally comprised three valves - a "slide valve", incorporating a "graduating valve" and a
"regulating valve". It also has functions - to release the brake, to apply it and to hold it at the
current level of application. The triple valve contains a slide valve which detects changes in the
brake pipe pressure and rearranges the connections inside the valve accordingly. It either:

 recharges the auxiliary reservoir and opens the brake cylinder exhaust,

 closes the brake cylinder exhaust and allows the auxiliary reservoir air to feed into the brake
cylinder

 Or holds the air pressures in the auxiliary reservoir and brake cylinder at the current level.

The triple valve is now usually replaced by a distributor- a more sophisticated version with built-
in refinements like graduated release.

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BRAKE APPLICATION

The driver has placed the brake valve in the "Application" position. This causes air pressure in
the brake pipe to escape. The loss of pressure is detected by the slide valve in the triple valve.
Because the pressure on one side (the brake pipe side) of the valve has fallen, the auxiliary
reservoir pressure on the other side has pushed the valve (towards the right) so that the feed
groove over the valve is closed. The connection between the brake cylinder and the exhaust
underneath the slide valve has also been closed. At the same time a connection between the
auxiliary reservoir and the brake cylinder has been opened. Auxiliary reservoir air now feeds
through into the brake cylinder. The air pressure forces the piston to move against the spring
pressure and causes the brake blocks to be applied to the wheels. Air will continue to pass from
the auxiliary reservoir to the brake cylinder until the pressure in both is equal. This is the
maximum pressure the brake cylinder will obtain and is equivalent to a full application. To get a

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full application with a reasonable volume of air, the volume of the brake cylinder is usually
about 40% of that of the auxiliary reservoir.

CHAPTER 6

BOOGIE SECTION

This shop manufactures boogies for metro, ACEMU and Indian railways coaches. The metro
boogies are only assembled in this shop. This section of the train has to withstand fatigue
loading. Thus components fail much before they reach their yield point. Thus a factor of safety
around 10 is maintained. The input to this section is the wheel set which is manufactured in the
rail wheel factory for the Indian railways. The boogie wheel set for the metro is imported from
voith, Germany. The frame is brought from the Siemens factory in Aurangabad. The side frame
of the boogie is assembled using automatic submerged arc welding. It uses a wire spool of
TCMS.current:550-600A, voltage-20-25V.Granular flux is initially poured in order to protect the
weld from oxidation.

Parts of the metro boogie

1. Traction motor.

2. Air balloon (secondary suspension)

3. Frame.

4. Speed sensor

5. Bearing assembly.

6. Primary suspension.

7. Levelling valve attachment.

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Once the welding is done, there is a hydraulic straightening machine which removes the
deformation caused due to welding, this is an important consideration concerning the alignment
of wheels. All the components of the boogie structure is welded using MIG welding. The braking
linkages are then attached. The secondary suspension is also attached.

The bearing (roller) assembly is fitted to the wheel set.It is used to reduce friction and also to
support the journal. The parts of the bearing are heated to 398K in an induction heater. Once the
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assembled bearing cools it contracts thus giving an interference fit. There is grease applied
between the parts of a bearing.

Bearing assembly

TESTING

The boogie is tested for tare load and full load, the measurements of deflection are taken and it is
then compared with standard (with some tolerance)

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SHEET METAL

Shearing: Removal/cutting of unwanted material and retaining the required portion.

Pressing: It is operation based on the shaping of sheet metal by plastic deformation, the
deformation is achieved by forcing the sheet metal into a formed die using punch. There are two
types of pressing machines

 Punch press

 Brake press

Grinding: It is an abrasive machining process that uses grinding wheel as the cutting tool.

Laser Cutting: is a technology which uses laser technology to cut the materials and is used for
industrial manufacturing process. Laser cutting works by directing the output of a high power
laser by computer, at the material to be cut. The material either melts, burns or vaporizes away or
is blown away by jet of gas. Cutting gases:

 Oxygen for M.S

 Nitrogen for S.S and Al

Maximum cutting thickness for different materials are:

 Mild Steel- 20mm Raw material Shearing Pressing Grinding Required material

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 Stainless Steel- 8mm

 Aluminum- 6mm

The input to this plant is the sheets of varying thickness that can come as plain, perforated or
with certain impressions. These sheets are brought from JSW, Bellary or SALEM steel plant.

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 CHAPTER 7

MACHINING SECTION

Most of the major assemblies require machined components which is performed here.

1. CNC turning machine-it is a computer numerically controlled lathe enclosed in a casing.

The work piece is held in place by the chuck. There is turret head which houses different
tools. For every turning operation a program is fed. During turning the screen in the
control panel indicates the instantaneous x and z co-ordinates.

2. Stretch forming-the work piece is stretched over a die and hence takes the shape of the
die. Depending on the die shapes different formed products can be obtained.

The machine contains two hydraulically controlled jaws which are moved backwards such
that the work piece acquires the shape of the die. Forming is preferred to welding as it is a
stress relieving operation. Machine used: Cyril bath,USA.

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 3. WMW machine: it can used for both boring as well as for milling operation depending on
the tool fixed to the spindle. It can be moved in all three directions
4. Radial drilling and reaming machine
5. Shaping machine-it is used to obtain various shapes on the work piece such as concave,
convex,T-slot,V groove,chamfers.cutting takes place only in the forward stroke. It is hydraulically
controlled.
6. Milling machines
7. Surface grinding and honing

CHAPTER 8

TEST TRACK

Tests

1. Train
 Controlling cab
 Start of/ shut down/ reset/ CCD operation
 System status indication
 MCB status monitoring
2. Interior and Lighting
 Head and cab main light
 Tail light or flash light
 Driving console light
 Saloon light
 Wind screen wiper
3. Gangway and Coupler
 Unit end coupling
 Circuit test
4. Traction system
 Speed control
 VVVF control
5. Brake system

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  Compressor control
 Brake loop
 Emergency brake loop
 Parking brake
 Horn, brake control
6. Auxiliary electric system
 APS
 Battery control
 Shore supply

CHAPTER 9

QUALITY DEPARTMENT

The work of this department runs parallel to production. The engineers in this department
form a part of the inspection team that perform the stage wise inspection in order to clear the
product to the next stage of production. For every stage of manufacturing this department has
an ITP (inspection test plan).According to this the inspection process is carried out. The
general contents of the ITP include the following.

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 1. Scope-To check/inspect that the products conform to the technical specifications and the
relevant procedures.

2. Abbreviations and definitions that are used in the ITP are explained.

3. Control of applicable documents and drawings-documents and drawings which are

applicable to each inspection test are designated in the table of ITP.BEML will also maintain
the latest drawings and documents for the customer’s requirement.

4. Requirements, standards and specifications-the ITP is prepared based on technical

specifications, test methods etc.

5. General inspection/test process-All major assemblies and sub assemblies, detail parts shall
be verified by QC officials and the record for the same shall be maintained. If there are non-
conformities of products and process, inspector will issue non-conformity report and notifies
to the production and planning departments. They rectify it and then again it is verified by
the QC officials and the record for the same shall be kept.

During the inspection there will be customer inspection points, where only after the customer
inspects and is satisfied with the product can it proceed to the next stage of production. The
inspection point will be notified to the customer through a RIT (request for inspection/test).If
the customer wants to inspect randomly he will notify BEML. The ITP contains a flow chart
indicating customer verification points. It also contains the inspection check sheets for
various components which contain specifications that every product should confer to.

The department also conducts CVI (complete vehicle inspection test).Besides this it also handles
customer feedback information and suggestions.

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 CHAPTER 10

METROLOGY DEPARTMENT
As the name suggests metrology is derived from the word meter. It deals
with measuring instruments. The main function of this department is the
calibration of all the measuring instruments used in various shops. The calibration
is carried according to Indian standards. Some of the instruments used are
1. Gauge bocks-these are used as master for calibration of vernier calipers. A
picture of it is shown below. They can come in different sizes. The desired
dimensions can be obtained by joining two or more of these. They are available in
grades which vary in their level of accuracy. Grade 2, 1,0,00 are arranged in the
increasing order of accuracy. Each of these set can cost up to a lakh.

Gauge block

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2. Vernier calipers-these can be analog or digital. They are used for four
measurements. They are inside diameter, outside diameter, depth and step
measurements. The least count of this device ranges up to 0.01mm.
3. Thread plug gage-there are two of these gages-GO and NO-GO. These are used
to check whether the pitch and diameter of the nut is up to the required dimensions.
It also acts as a master for the ring gage. The difference between the diameters of
GO and NO-GO side defines the tolerance required.
4. Ring gauge-these are used to check whether the bolts are according to required
dimensions.
5. Inside and outside micrometer are used to give micrometer accuracy.

Vernier callipers

Ring guage Thread plug guage

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Screw gauge

Dial guage used to measure deflections.

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 CHAPTER 11
PRODUCT DESIGN (PD) DEPARTMENT
Once the contract is obtained by the marketing division it is reviewed in the pre-
contract review meeting in which all the managers of different departments discuss
the following:
1. Delivery schedule.
2. Manufacturing capabilities and parameters.
3. Constraints should be added (if needed).
The PD department then studies the general specifications required by the
customer(a general outline of the product is given by the customer).The engineers
then come out with the required manufacturing drawings specifying the
dimensions,size,shape and the materials(BOM) to be used. These have to be
approved by the customer or his agency (RDSO in case of Indian railways).
Then a prototype of the product is made and is inspected by the customer’s agency
(RDSO) .If any changes are required it is made accordingly. Once satisfied the
customer’s agency (RDSO) gives the approval for bulk production.

ECR AND ECN

In case for any reason the manufacturing section wants to make a change in the
product, it is communicated to the PD department by an ECR (engineering change
request) through the ERP.This is then analyzed by the department, if any change is
required it is communicated to the required departments by an ECN (engineering
change notice) which specifies the change made. The old blue prints are now
replaced with the new one and again the new blue print is sent to the required
departments.

CHAPTER 12

PLANNING DEPARTMENT
This department mainly performs two main functions
1. Materials planning-involves the decision to decide whether the components
required are to be manufactured in house or to be brought from vendors.
2. Facilities planning-involves plan for machineries, material flow, man hours
availability etc
3. Scheduling-based on monthly basis.
The above mentioned functions are carried by an ERP-SAP.Intially the input is
entered. Input may include the process used, quantity, material, sub-assemblies and
components, cost etc.

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 The output of the ERP run is the planned order and the product order which
gives cost of the entire process, components to be procured, components left
in the stores, products to be manufactured per month etc. Once any
transactions are carried it is updated accordingly.

CHAPTER 13

INTERNSHIP AT BEML Limited - a learning Experience

As envisioned by our first PM, Pt. Jawaharlal Nehru, BEML Limited has proved to be true
one among the modern temples of engineering of India and BEML has proved beyond doubt
that they are no less than their competitors in the private sector. As I have seen and
experienced, there is no dearth of expertise, talent, professionalism and dedication of the
workforce towards accomplishing the tasks and targets in meeting delivery of products to its
various customer segments.

Today, I am proud to be associated with this esteemed organization as an intern and I am

fortunate to have the exposure across most of the departments and its industrial functioning.
Overall it was a good learning and rewarding experience.

This interaction gave me an insight and first-hand experience of industrial scenario outside
the institute curriculum. In addition, the exposure gave me the practical knowledge into the
overall functioning of the organization, human behavior in industry and also helped us co-
relate theoretical concepts of classroom and practical approach to industrial production.

The entire duration of four weeks in BEML was professionally managed by all the
responsible persons I came across, very informative and I have no doubt, it will retain its
significance when I embrace my professional careers as an engineer.

In doing so, I gratefully acknowledge the large heartedness of this institution for giving me
an opportunity to complete this internship.

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