TYPES OF WAGONS

Different wagons are used for transporting different types of material, depending upon the size, shape and nature of protection required during the course of transportation.

Covered Wagons used for Food Grains, Cement etc. (BCN, BCX etc.)

Flat Wagons used for Iron, Steel products, containers (BRN, BFKN etc.)

Tankers wagon used for transportation of Petroleum Products, Naptha, Ammonia, Phosphorus etc. (BTPN, BTPH etc.)

Open wagons with Rapid Bottom Discharge System primarily used for Coal and iron Ore (BOBR etc.)

Open Wagon with side (controlled) discharge used for unloading ballast on the railway tracks (BOBY etc.)

Container wagons

These wagons are specifically designed to carry ISO standard containers. They have a flat bed and locking mechanisms to secure the containers during transit used for transporting perishable goods like fruits, vegetables, dairy products, pharmaceuticals, etc. They have insulated walls and refrigeration units to maintain a controlled temperature. with a covered structure are specifically designed for transporting commodities like cement, fly ash, granulated slag, etc. They have bottom discharge gates for easy unloading. used for controlling the speed and providing safety during train operations. They are equipped with brake systems and are typically placed at the end of the train. They also serve as a living space for the train guard.

Periodical overhauling (POH)

Periodic overhauling of wagons refers to the maintenance and repair activities carried out at regular intervals to ensure the safe and efficient operation of the wagons. These overhauls are conducted to inspect, repair, and replace components, as well as to perform necessary maintenance tasks. The specific frequency and scope of overhauling can vary depending on factors such as the type of wagon, its usage, and the guidelines and policies of the railway authorities

For

• OPEN WAGON: POH is done every 4 years

• CLOSED WAGON: POH is done every 6 years

• BOXN : POH is done every 4 years

• BCN & BTPN : POH is done every 6 years

The Average time for POH of wagon is 9 days.

Process Layout

Stripping Shop

Here the main motto is to identify the various corroded parts of the shell. To identify them stripping of various components such as berths, wash basin, lavatory fittings, window shutters, side panels, flooring, electrical auxiliary equipment etc. are removed manually by hand operated tools or by weld cutters.

• Inspection of wagon

• Damaged parts are marked

• Gas cutting and plan cutting is done

The oxy fuel cutting is performed

BOGIE REPAIR SHOP:

This shop deals with the maintenance and repairing of Bogies. A bogie is a chassis or framework carrying wheels attached to a vehicle, thus serving as a modular sub assembly of wheels & axles. The bogies being manufactured by ICF/RCF have been accepted as a standard of Indian railways.

Key components of a bogie include:-

Bogie frame: - This can be of inside frame type where the main frame and bearing are between the wheels, or (more commonly) of outside frame type where the main frame and bearing are outside the wheels.

Suspension: To absorb shocks between the bogie frame and the rail vehicle body. Common types are coil springs or rubber airbags.

Brake Equipment: Brake shoes that are pressed against the tread of the wheel, and disc brakes and pads

BODY REPAIR SHOP:

A body repair shop in a wagon workshop is a dedicated facility or area where the bodies or exterior structures of railway wagons are repaired, refurbished, or modified. It is responsible for addressing various issues related to the wagon's body, such as damages, corrosion, dents, and structural repairs

The types of welding used are:

• Gas welding (oxy acetylene)

• TIG welding

• Consumable electrode welding

These types of welding operations are performed

CBC SHOP (CENTER BUFFER COUPLER) :

CBC (Centre Buffer Coupler) shop refers to a specific area or facility within the workshop that is dedicated to the maintenance, repair, and overhaul of centre buffer couplers. The centre buffer coupler is a type of coupler used to connect railway wagons and provide the necessary flexibility and shock absorption during train operations

• Coupler is a mechanical device used to interconnect rolling stock to form a train and to transmit draft and buffing forces

• Knuckle is fit with coupler head. Used to couple two coupler heads of two wagons.

• Draft gear arrangement has to minimize the impact loads owing to the starting jerks reaching the wagon under frame. it has to perform this function smoothly without causing damage to the wagon structure

• Yoke part must be free from cracks, fractures, sections broken out and service notches. Front of yoke pin bole to butt inside surface length must be as follows.

Minimum - 786 mm, Maximum - 787.5 mm

Inspection

 Visual Inspection

 Gauging Inspection

 Non Destruction Testing

Die Penetrant Test & Top (Drop) Hammer Testing

WHEEL SHOP:

A wheel repair shop in a wagon workshop is a specialized facility or area dedicated to the maintenance, repair, and refurbishment of railway wagon wheels. The wheels are a critical component of the wagon's running gear, and the wheel repair shop ensures their safe and efficient operation. Here are some key aspects of a wheel repair shop in a wagon workshop:

• Wheel Inspection: The wheel repair shop performs thorough inspections of wagon wheels to assess their condition. This includes checking for wear, damage, cracks, out-of-roundness, or any other issues that may affect their performance and safety.

• Wheel Truing and Profile Restoration: If the wheels are found to be out of alignment or have uneven profiles, the wheel repair shop performs truing and profile restoration. This involves using specialized machinery and tools to reshape the wheel profile and restore its proper geometry.

• Wheel Resurfacing: Over time, wagon wheels can develop surface defects, such as pitting or surface cracks. The wheel repair shop addresses these issues by resurfacing the wheel treads. This process involves removing a thin layer of the wheel surface to eliminate defects and restore a smooth and uniform tread.

• Wheel Bearing Replacement: The wheel repair shop handles the replacement of wheel bearings when necessary. Wheel bearings are critical for ensuring smooth rotation and reducing friction. If bearings are worn out or damaged, they are replaced with new bearings to maintain optimal wheel performance.

• Axle Inspection and Repair: In addition to the wheels, the wheel repair shop may also inspect and repair wagon axles. Axles play a vital role in supporting the weight of the wagon and transmitting the forces between the wheels and the wagon body. Any defects or damages found during inspection are addressed through appropriate repair or replacement.

• Wheel Balancing: The wheel repair shop may perform wheel balancing to ensure even weight distribution and minimize vibrations during wagon operation. This process involves adding or removing weights to balance the wheels, enhancing their stability and reducing wear.

• Wheel marking and Identification: After repairs and refurbishments, the wheel repair shop ensures proper marking and identification of the wheels. This includes stamping identification marks, wheel specifications, and other relevant information on the wheel surfaces for easy identification and traceability.

PAINT SHOP:

A paint shop in a wagon workshop is a dedicated facility or area where the painting and finishing of railway wagons are carried out. It is responsible for applying protective coatings and providing corrosion resistance to the wagon's exterior surfaces. Here are some key aspects of a paint shop in a wagon workshop:

• Surface Preparation

• Paint Application

• Protective Coatings

• Drying and curing