STRUCTURAL SHOP

This shop plays an important function in the

production process by carrying out different
operations as per the requirements.

WELDING:

This is the art of joining

two metals by the application of heat.
Heat makes the metals to flow and
then with or without application of
pressure the joining operation is being
carried out.
The different types of welding operations
carried out are:
1.
2.
3.

Electric arc welding

Gas welding
Submerged arc welding

ELECTRIC ARC WELDING:

In this type of welding process no
mechanical pressure is applied for joining
the metal.
The metal pieces to be joined are heated
locally to the melting point temperature by
creating an electric arc and then allowed to

solidify to form the welded joint. In some

cases an additional material called filler
metal is used in addition with the metal
pieces to form the joint.

GAS WELDING:
In company generally CO2 gas welding is
performed that is called MIG (Metal Inert
Gas) welding.
Here CO2 is used as a shielding gas.
The arc is struck between the electrode and
the workpiece and shielding is provided by
the gas developed during combustion of flux
plus the CO2 gas fed around the arc for this
purpose.
While welding is done by flux coated
electrode a magnetized granular flux is fed
into the arc through the gun nozzle and
there is attached itself to the electrode.
The coating is provided to safeguard the
electrode from contamination. The arc and
weld are protected against the atmospheric
contamination by the shield of CO 2 gas. The
method of feeding the electrode wire into

the arc is again similar to that in the

standard MIG welding process.

ADVANTAGES:
1.
It is a fast welding process.
2.
The decomposition rate is high.
3.
Penetration of arc is deep.
4.
Minimum
edge
preparation
required.

is

SUBMERGED ARC WELDING:

It is basically an arc welding process in
which the arc is struck between a
consumable metal electrode and the
workspace.
For starting welding the pieces to be joined
are placed in position, flux from the hopper
is then fed on to the joint through the flux
feeding tube.
The electrode wire is fed into this blanket of
flux and the arc is struck. The heat
generated melts the metals, the surrounding
flux granules and the filler metal. The latter
form the weld bead and the former fuses in
to form covering of the slag over the bead.

It protects against the atmosphere until it

cools down. The process continues as the
welding head advance along the joint with a
proper speed, the flux hopper unit sliding
ahead of the arc. The entire flux fed by the
hopper is not melted. This unused part of
the flux is been collected by another unit,
following the welding head, and fed back to
the hopper for further use. After the slag is
cooled down it is removed.
This process is suitable for welding of low
carbon steels, stainless steels, medium
carbon steels, copper alloys, nickel and
nickel alloy etc.

ADVANTAGES:
1.
As the arc is completely submerged
so no shielding is needed.
2.
Shallow grooves can be used for
making joint, requiring less consumption
of filler metal.
3.
Higher welding speed can be applied,
so welding time is reduced.
4.
Deposit rate is very high.
5.
No chance of welding spatter.

6.
Flux act as a deoxidizer to purify the
weld metal.

DISADVANTAGES:
1.
Flux may get contaminated and lead
to porosity in the weld.
2.
Slag removal is an additional follow
up operation.
3.
To obtain good weld the base metal
have to be cleaned and made free of
dirt, oil, rust.
4.
It is not suitable for welding of metal
thickness less than 4.8mm.

WELDING MACHINE SPECIFICATION

Oil cooled welding transformer:
ESAB 450 OC natural oil cooled, manual
single arc welding transformer. It is portable
source of welding current where single
phase ac mains supply at 390-440 volts, 50
Hz is available.

TECHNICAL SPECIFICATIONS:
INPUT:

Supply voltage- 440 V

2 line of 3 phases
50 Hz
Rating at 60% duty cycle- 32.5 Kva
Primary current-

78 A

OUTPUT:
Open circuit voltage- 80 V
Welding current range- 60-450 A
Type of welding current- step less
Insulation class- A
Type of cooling- Natural oil
Weight- 235 kg
Oil required- 200L

CO2 MACHINE SPECIFAICATIONS

Model- Surac daiden move 400
Rated current- 400 A
Rated input power- 20 Kva (3 Phase)
Frequency/Primary current- 50/28 Hz/A
Rated duty cycle- 60%

Output current range- 50-40 A

Output voltage range- 14-36 V
Dimension- 375X 560X 730 (w X d X h)
Weight- 100 kg
Wire feeding speed- 1.5-15 m/min

WELDING TORCH
Rated current- 400 A
Welding wire- 0.8, 1.2, 1.6 m
Cable length- 3m
Cooling style- Air cooled

SHOT BLASTING
After complete assembly and before
painting the wagon is sent in the shot
blasting shop. In there the wagon is sent in
the shot blasting room. The shot is thrown
on the body of the wagon at very high
pressure and speed.
The shot is nothing but a dust of iron whose
diameter is near about 0.5 to 0.7 mm.

The shot is shot in the shot storage tank due

to the pressure difference which is created
by the air compressor. The shot is poured on
the blade which is present in the shot
blasting room. The blade is moved at very
high speed. When the shot is poured in the
blade it is discharged at a very high speed.
Used shots are not reused.

OBJECTIVES
To make
To make
Improve
Improve

good surface finish

smooth surface
material quality
machinability

CRANE MAINTENANCE
1- Preparation for the operation :
The cranes are operated by manipulating
the controller, governing each type of
motion. Before operating to start the crane
maintain the following rule.
Press the bottom switch to close the main
circuit magnetic contractor in this case
however if the controller handle is not at

0 notch, the main circuit magnetic

contractor cannot be closed by pressing
bottom switch.

OPERATION:
HOISTING AND LOWERING:
For hoisting slowly move the controller
handle across the notch from 1st motor to
last motor so that the resistance are cut
off in the step (in case of slipping motor).
Controller should move in the reverse
direction for lowering through zero
notches. In case of floor operated crane,
push button is inching type and respective
should be pressed and full speed will be
achieved by cutting of resistance in step
through automatic timer.
TRAVERSING AND TRAVELLING
For this also controller should be moved
slowly across the notch to left or right
depending upon the desirable trolley or
bridge movement.

It is desirable to bring controller on zero

position before reversing in case plugging
control is not provided.
For push bottom crane respective should
be pressed for desired motion and
resistance will be cut off in step through
timers automatically.

2.
SAFETY
DEVICE:

AND

PROTECTIVE

In the following case the operating circuit

is opened and main circuit is cut off.
a)
When the floor switcher has been
pressed by the operator.
b)
When stopping, push bottom switch
has been pressed.
c)
When the over current relay or
enclosed fuse has functioned.
d)
When
the
power
has
been
interrupted.
After a limit switch is in.
Above has functioned, preparation can be
made for resumption of returning the

traversing or travelling controller is in zero

position and pressing (on).
Again in this case even if an attempt is
made to operate in the direction in which
the limit switch has gone off. Operation
will not be possible.

3.EMERGENCY STOP:
In case of an emergency, quickly press the
stop push button switch (off) this will cut off
main ckt.

4.COMPLETION OF OPERATION:
When all operations are completed, perform
the following routine before leaving the
crane.
I. Press the button for stopping to release
the air circuit brakes.
II. Break all of the fuse free breaks.
III. Check to make sure that the entire
controller is at zero position and there is
no abnormal overheating of any of the
press of the electrical equipment.

SAFE HOISTING PRACTICES

Hand operated, elastic hoists and trolley of

all types are designed keeping in mind the
safety of the operator. Our own safety and
that of our fellow workers will be assured
when
over
head
material
handling
equipment is used as recommended by the
manufacturer.
Some of the safety rules are enlisted as
follows:
i. The immediate danger is the possible
failure of some load carrying parts.
Overloading might also start a defect
which could lead to serve future failure
event less than rated capacity.
ii. Do not use any overhead material
handling
equipment
for
handling
personnel.
iii. Conduct a periodic visual inspection for
sign of damage or wear.
iv. Do not use the hoisting cables or chains
as a substitute for slings.
v. Whenever the host is lowered in such a
manner as to take the load of the wirerope.
vi. Always inch the hoist into the load.

vii. Limit switches are for emergency use

only and should not be tripped during
the normal operation.
viii. Be sure the hoist raises and lowers
properly when the corresponding buttons
for controllers are operated.
ix. Centre the hoist over the load before
lifting.
x. The wire ropes for load handling should
not be placed against portions of the
load which may cause them to move or
slip off.

GAS CUTTING
In the gas cutting department, generally
thick mild steel plate or the plate which
are long i.e., large in dimension.
In here raw material to be cut are sheet
metal or plates and are cut according to
the dimension or draft material list. Draft
material list are prepared by on the basis
of minimum scrap and the minimum
utilization of sheets and plates.

OXY-ACETYLENE TORCH CUTTING:

This is the most common and convenient

method now a days. The principle on
which it is based on is that oxygen has a
strong affinity for iron and steel at
elevated
temperature.
At
high
temperature oxygen forms iron oxide with
iron which has low melting temperature.
As a result at high temperature it melts
out and the metal is cut.
Thus the steel is first heated to a red
colour and then a jet of pure oxygen is
blown upon the surface, instantaneously
the steel is burned in an iron oxide slag
like appearance which under pressure falls
down and steel is cut. The pressure is very
rapid and metal up to thickness of 7.5cm
can be cut by this process. The nozzle is
kept above the 4mm of the work.
For 6mm thick mild steel plate 1.2mm
nozzle and cutting speed of 30-45 m/hr is
employed with acetylene consumption of
1.38 to 2.7 m3/hr. As the thickness
increase all the parameters increase.
This process has become versatile. Now
due to its simplicity several cutting

machines has been employed based on

this principle which are automatically
controlled by the movement of the torch
to cut any desired shape.

GAS CUTTING MACHINE

1. TEMPLATE CUTTING MACHINE:
It cut the metal plate according to the
template of the component or item. In the
template
cutting
machine
small
components are cut by good accuracy and
finishing. This type of machine is used for
mass production. This type of machine do
not require high skilled operator.
In this type of machine the template to be
cut is placed on the top of the machine.
Machine has an adjustable case for
template for the setting of different type of
templates.
D.C power 220V is used for this type of
cutting machine. It has D.C motor panel to
regulate the D.C motor speed. The motor
generates the magnetic field and the roller
moves around the templates because the

roller becomes the magnet due to the

magnetic field generated by the motor.
The movement of the arm of the machine
depends upon the roller movement. Thus
the roller guides the movement of the arm
of the machine. Arm of the machine
consist of oxygen and acetylene release
nozzle and control knob.
Arm of the machine upward, downward,
leftward, rightward motion. Metal plate
which is to be cut is placed on the
machine table and is marked at the point
at which cutting is to start. Adjust the arm
of the machine and the gas release knob.
Motor speed and distance between plate
and nozzle point is controlled and
maintained according to the thickness of
the plate.

PUG MACHINE
By this type of machine straight or
horizontal plates are cut. Pug machine
travel on the fixed path which is placed on
the metal plate which is to be cut.

The movement of the PM on the well

defined path is achieved with the help of a
universal motor. Universal motor is fitted
with the pug machine.
The speed of the universal motor is
controlled by thiristor controlled system.
Speed is controlled by the operator by
revolving the knob which is present in the
thiristor control system which depends on
the thickness of the plate.

BOBRN TYPE WAGON

SPECIAL FEATURES OF BOBRN
WAGON:
1.

Bottom discharge doors

3.

Bogies

4.

Coupler

Doors
are
electro-pneumatically
operated by the line side equipment.
Doors operating pipe shall be changed
from the locomotive with compressed air
at a pressure of 6.2 bar.
2.
Brakes
Single pipe graduable release air brake
system fitted with auto slack adjuster
and automatic load sensing device to
cater for the brake power requirement in
empty and loaded condition.
2-axel cast steel bogie type CASNUB-22
NLB of R.D.S.O specification no. WD-21CASNUB-22NLB-BOGIE-93 REV which is
fitted with the spring plank, long travel
helical spring, damping device, taper
roller cartridge bearing of R.D.S.O
specification.

High tensile centre buffer coupler is

used.

5.

Bottom discharge door

Doors are to be operated by manual

pneumatic valve. Door operating pipe
may be changed from the locomotive
with compressed air at a pressure of 6.2
bar.

5
6
7
8
9
10
11
12

Corner gusset
Bolster assembly
Diagonal
Head stock
Centre sill
End ridge x end
assembly
Cross ridge bracing
Bracket for Bp

4
2
4
2R,2L
1
1R,1L
4
2

BRAKING DETAILS OF BOBRN

TYPE WAGON
Air brake:
1.
Estimated weight of wagon25.61
tonne
2.
Brake cylinder size-355 mm
3.
Number of cylinder used-1
4.
Effective piston force;
i. Under tare-2016 kg
ii. Under gross-3600 kg
5.
Rigging efficiency 90%
6.
Rigging ratio
Bogies casnub-10.28
7.
Total brake block pressure
i. Under tare-1775 kg
ii. Under gross-32414 kg

 DOOR OPERATING
ARRANGEMENTS
Parts:

i.
ii.
iii.
iv.
v.
vi.

Air receiver tank.

Pneumatic control valve.
Air cylinder.
Dirt collector.
Door pipe.
Cut off angle cock.

Hot shop
Hot shop consists of bending with the help
of forging, cold-heading, forming, punching,
coining and heat treatment.

DS SHOP
It means Drop Stamping Shop. In this
particular shop forging stamping, flashing,
pouncing etc are carried out with the help of
forging
machine(both
hydraulic
and
mechanical type).

FORGING:
It is defined as the controlled plastic
deformation
of
metals
at
elevated
temperature into a predetermined size using
compressive force exerted through a type of
die by a hammer, a press or a upsetting.

UPSETTING:
It is done to reduce the height of forging and
to increase its diameter. Usually completely
overlapping tool is used in this process.

IMPRESSIONS DIE FORGING:

It is used when the work-piece is small and
intricate in the shop. A piece of heated
metal is placed on the lower die is blocked.
The metal placed into the shop of the die
get blows from a machine hammer.

FORGING PRESS:
It defers from a forging hammer with
respect to the energy which is applied more
gradually to the work piece which is heated
only one time in each impression.

BLANKING:
This is the operation which is carried out on
the presses and which consists of cutting
the outside contour of a stamping.

PUNCHING:
This is also a press operation which consists
of cutting holes of various shapes.

MECHANICAL FORGING PRESS:

It consists of a heavy and rigid frame, an
electric motor to supply energy and a
flywheel to store energy. The rotary motion

can be converted into vertical movement by

electrical shaft, crank shafts.

HYDRAULIC FORGING PRESS:

In this the ram is operated by a large piston
which is driven by high pressure oil. The
piston movement is quite slow in the
process.

PS SHOP(A&B)
It means Press Stamping Shop where the
forming processes are carried away.
Forming processes means converting the
metal plates into desired shape and size by
applying high pressure with the help of the
punch and die on the hot metal sheets or
plates. In this department two brake presses
and two hydraulic presses are used to
perform the job. Brake presses have a
capacity of 300 tonnes.
In the hydraulic press, pressure is applied on
two sides of a sheet. The range of the
application is large and the thickness of the
materials which can be hot pressed may

vary widely, provided equipment is available

for required pressure and size.
Two types of hydraulic presses are in use. In
the first type the steel is gripped in
stationary jaws and is subsequently
stretched by moving the form block
vertically with a plate actuated by hydraulic
piston placed in a cylinder. In the second
type there is an advantage of positioning
the jaw easily.

SMY SHOP
In the SMY shop different types of
operations
like
upsetting,
forging,
straightening etc are carried away. In this
shop there is one oil furnace which is used
for the upsetting operation.

BENDING:
It is one of the most important process and
is very frequently used. It may be classified
as sharp corner bonds or more graduable
bonds.
When the material is bonded by hammering,
the outer and inner surface does not remain

same. The inner surface is shortened while

the outer surface is stretched which causes
bulging at the side of the inner surface and
increase in the radius of the outer surface. If
a sharp corner is required an additional
metal is required in that place.

UPSETTING:
This is very useful operation for the parts
having uniform cross section throughout and
some head at the end point on the end. E.g.
a bolt rear axle drive shaft having flanged
edge. In upset forging operation a bar of
uniform section is gripped in the fixed end of
the die so that the requested end could be
projected. The
pressure is applied at the
heated end thus causing to be upset or
forced to get desired shape, for which the
stock is placed between the fixed and the
movable die grips of the bar firmly when it is
closed.

PRODUCTION PLANNING
AND CONTROL
Production planning means planning of
actual production of the component for
which an actual demand has occurred. This
quantity must be produced not only in
required quantity but also in accordance
with specification and in the time to meet
customers delivery requirements.
If more than adequate capacity is provided
in equipments and machinery, it becomes a
simple task to show that an efficient use is
done of the available capacity to make the
output.
However in actual practice many errors and
gap may occur in case of the available
capacity i.e., it may be inadequate and
unexpected in local times for purchase
input. Labor efficiency may be lowered than
which is estimated. So well thought out
plans are made to meet all eventualities.
In production planning the production
activities themselves and the production

control should be integrated and blamed.

Planning should carefully analyse the
requirements and the ability to produce.
Productions should coordinate and organise
related activities and production control
should monitor programs and performance.
In production planning the actual progress
should not coincide with the schedule time
and rate of progress.

NEED FOR PPC

1.
Customer demand is likely to defer in
quantity and delivery schedule and to
meet this it may require a longer
fluctuation in the production level.
A better alternative system should be
planned for production purposes in the
future for steady operation with minimum
inventories.
Production
operation
are
subjected to a variety of uncertainties such
as emergency orders brake down. PPC
should also provide a way to take this factor
into consideration.

OBJECTIVES OF PPC:

1.
Determine the expected capacity of
each work centre.
2.
Allocate this capacity in each broad
category of manufacture.
3.
Prepare sequential local statement.
4.
Keep a record of each work.
5.
Convert
the
above
into
a
presentation.

PROCEDURE OF PPC:
Purpose:
To ensure that planning of production
process are suitable for providing input in
manufacturing activities so that the delivery
schedule and product quality both are
maintained.
Scope:
These processes are applicable to;
1.
Planning of production target.
2.
Material planning for major brought
out/ non free issue of raw materials and
maintaining availability status of the
same.
Method:

1.
Based on order book position as
received from commercial department.
2.
The annual plan is subsequently
revised in normally and half yearly basis
based on the production basis.
3.
Monthly production plan is made
referring to the annual plan for all the
product lines for wagon order.

PURCHASE DEPARTMENT
Delegation of financial powers for purchase:

Up to
Up to
Up to
Up to

Tender value By whom to be

exercised
1 lacs
By
Dy
purchase
manager
2.5 lacs
By purchase manager
5 lacs
By chief purchase
manager
10 lacs
By
Dy
G.M.
manufacturing

APPROVAL LIST OF SUPPLIERS:

To accelerate procurement it is essential
that an exhaustive list of suppliers should be
prepared and maintained by purchase
department as it works.
i. In order to complete the list of suppliers,
advertisement shall be relisted in a
newspaper
inviting
application
for
registration, with the company, as
approved suppliers for various type of
materials,
equipments
etc.
The

application should be made on the

prescription form as per system.
ii. On receiving the application from the
interested firms, the same shall be
scrutinized to see that the same are
completed in all respect and that the
replies to the questionnaire are not
evasive.
iii. Factors which matters in considering the
application for registration as approved
suppliers are:
a)
Management, financial standing
and the capacity of the firm.
b)
Types of customers and business
holders.
c)
Specifications regarding to whom
the products are manufactured.
d)
Servicing testing facilities.
e)
Income tax clearance certificate.
Etc

QUALITY CONTROL
It is an effective system for coordinating the
quality
maintenance
and
quality
improvement effort of the various in an
organisation so as to enable production at
the most economic level which further
allows customer satisfaction.
Advantages:
1.
Improvement of product quality.
2.
Improvement of product design.
3.
Reduction in operating cost.
4.
Reduction in operating losses.
5.
Reduction
in
production
line
bottlenecks.
6.
Improvement in production moral.
Objectives:
1.
To determine size, material, design,
appearance, workmanship, finish and
other relevant properties.
2.
To ensure that the product of lower
quality may not go into hands of
customers.

3.
To carefully observe and analyse the
deviation from the set standard of
quality during manufacture.
4.
To apply corrective measure to
achieve the real mission of quality
control.

PRINCIPLES OF QUALITY CONTROL:

1.
To ensure that the standard of
measurement are uniformly applied.
2.
For determining the variation of
quality.
3.
A component personal takes the
responsibility for the quality of the
product.

DEGREE OF QUALITY:
1.
2.
3.
4.

Standards and inspection.

Inspection of materials.
Statistical techniques.
Inspection device.

QUALITY OF POLICY:
INSURE:
B.S.C.L is committed.

THROUGH:
Total customer satisfaction.

AT:
Quality production and timely supply of
rolling stock and associated service.
UNDER:
Competitive price.
THROUGH:
Structured quality management through
involvement of its committed employee
aiming at continual improvement.