ACKNOWLEDGEMENT

I owe a great many thanks to a great many people who

helped and supported me during the entire project.
I , , the student of Mechanical Engineering
DEPARTMENT, , am extremely grateful to COACH
REHABILITATION WORKSHOP , BHOPAL for the
confidence bestowed in me .
I express my thanks to the Principal of, JAI NARAIN
COLLEGE OF TECHNOLOGY, for extending his
support.
My deep sense of gratitude to PRINCIPAL,
TECHNICAL TRAINING CENTRE, COACH
REHABILITATION WORKSHOP (CRWS), BHOPAL
for their support and guidance. Thanks and appreciation
to the helpful people at different workshops in COACH
REHABILITAION WORKSHOP , BHOPAL for their
kind support.
My deepest thanks to Lecturer, the Guide of the project
for guiding and correcting various documents of mine
with attention and care.

DECLARATION
I, , student of B.E. (Mechanical Engineering)
hereby declare that the study of COACH
REHABILITAION WORKSHOP BHOPAL . The
work has been carried out under the guidance of
helpful people at different workshops in COACH
REHABILITAION WORKSHOP for their kind
support.

PREFACE
Summer Intership Project is a golden opportunity
for any B.E. student to know all the aspects of
industry concern. The main purpose of Summer
Internship Project is to develop a strong moral and
confidence in the student . Summer Intership
Project plays a very vital role in our life and it
proves to be very helpful in providing accessibility
to practical knowledge and to live as a
professionals.
In Summer Internship Project , every student
should go in-depth of the theoretical and analytical
aspect of his\her topic. It results in better
understanding about a particular field.
I have got a better chance to complete my four
weeks intership at COACH REABILITATION
WORKSOP, BHOPAL which has built a great
confidence in me .

CONTENTS
CHAPTERS
CHAPTER 1.
Introduction
Company Profile
CHAPTER 2.
Services offered by company
Features
Layout
CHAPTER 3.
Workshops , layouts and its applications.
Pocket yard
Lifting Shop
Stripping and PCR Shop
Bogie Shop
Wheel and baring shop

Body repair shop

Carpentry shop
Sell Component sop
AIR BRAKE shop
Paint shop
Furnishing shop
Final shop

INDIAN RAILWAYS
Indian
Railways
is
an
Indian stateowned enterprise, owned and operated by the
Government of India through the Ministry of
Railways.
It is one of the world's largest railway networks
comprising 115,000 km (71,000 mi) of track over a
route of 65,436 km (40,660 mi) and 7,172 stations.
In 201314, IR carried 8,425 million passengers
annually or more than 23 million passengers daily
(roughly half of which were suburban passengers)
and 1050.18 million tons of freight in the year.
Railways were first introduced to India in the year
1853 from Bombay to Thane.
In 1951 the systems were nationalised as one unit,
the Indian Railways, becoming one of the largest
networks in the world.

IR operates both long distance and suburban rail

systems on
a multi-gauge network
of broad, metre and narrow gauges.
It
also
owns locomotive and coach production facilities at
several places in India and are assigned codes
identifying .

COACH REHABILITATION
WORKSHOP BHOPAL
Coach Rehabilitation Workshop is located at Nishatpura
area, in the city of lakes Bhopal, which
is the political capital of the State of Madhya Pradesh.
The workshop is situated at a distance of 2 Km from the
Bhopal Railway station.
The Workshop was started in year 1989 at a project cost
of approx Rs.64.97 Cr for Mid Life Rehabilitation
(MLR) of Indian Railway Coaches. It has completed
more than 20 years of service to the Nation. CRWS has
so far turned out 6905 coaches including 420 AC
coaches.
During the year 2010-11 it has achieved best ever
production of 571 coaches.
During MLR entire coach furnishing is stripped off and
renovated. The bogie assembly and sub-assemblies are
repaired or reclaimed or replaced as the case may be,
based on the service & utility factor. Overhauling
activities includes heavy corrosion repair to the shell
body and under frame, renewal/repair on account of
furnishing, train lighting & painting. This activity results
in savings in repair cost in subsequent years of service
of coaches apart from providing improved
customer satisfaction for passengers.
The quality of coaches coming out of CRWS has had
excellent reputation over the years and now
it is being treated as benchmark for all other workshops
planning overhaul activity.

CRWS's quality,environmentand occupational health &

safety management systems continue to be
certified to ISO 9001, 14001 & OHSAS 18000. The
workshop layout is based onU-flow with majority
movement being on dummy bogies on merry go round
system.
Total budget allotment of the shop is around Rs.121
Crores for a year. The shop functions out of budget
provisions from railway board in the form of Rolling
stock program.
The committed workforce of the workshop has carried
out many innovative system improvements over the
years including in-housedevelopment of RFID based gate
attendance & incentive calculation system etc. The shop
has outsourced many activities over the years including
grit blasting of outer surface of shell, sand blasting of
bogie flames, retro fitment of air brakes, over hauling of
air brakes cylinders,screen of coach number printing etc.
A Regional Welding Institute for comprehensive training
of welders of various railways has been
set up and various modules are being operated in
workshop premises.

RAILWAY ZONES
The Indian Railways is divided into zones, which are
further sub-divided into divisions, each having a
divisional headquarters. There are a total of sixty-nine
divisions.[1]
Each of the divisions, is headed by a Divisional Railway
Manager (DRM) who reports to the General Manager
(GM) of the zone. A DRM can be appointed from any
services of Indian Railway, Indian Administrative
Service (IAS) and Indian Revenue Service (IRS) for the
tenure of 3 years but it can be exceeded on the
recommendation of Railway Board. Divisional officers
heading all departments viz. engineering, mechanical,
electrical, signal and telecommunication, accounts,
personnel, operating, commercial, safety, medical,
security branches report to the Divisional Railway
Manager. The DRM is assisted by one or two Additional
Divisional Railway Managers (ADRM) in the working of
the division.

There are 16 zones and the 68 divisions are listed below:[2]

Name of
Route
Sl. the
length Headquarter
Abbr.
Divisions
No Railway
(in
s
zone
Km)
Mumbai,[3] Bhusawal,
Central
[4]
1.
CR 3905 Mumbai
Pune,[5] Solapur,[6]
Railway
Nagpur[7]
East
Danapur,[8] Dhanbad,
2. Central ECR 3628 Hajipur
Mughalsarai,
Railway
Samastipur,[9] Sonpur
East
Khurda
Road,
3. Coast
ECoR 2572 Bhubaneswar
Sambalpur, Waltair[10]
Railway
Eastern
Howrah,
Sealdah,
4.
ER 2414 Kolkata
Railway
Asansol, Malda
North
Allahabad,[11]
Agra,
5. Central NCR 3151 Allahabad
Jhansi
Railway
North
Izzatnagar, Lucknow,
6. Eastern NER 3667 Gorakhpur
Varanasi
Railway
North
Jaipur,[12]
Ajmer,
7. Western NWR 5459 Jaipur
Bikaner, Jodhpur
Railway
Northeas
Alipurduar, Katihar,
8. t Frontier NFR 3907 Guwahati
Rangia,
Lumding,
Railway
Tinsukia
Delhi,[13]
Ambala,[14]
Northern
9.
NR 6968 Delhi
Firozpur,[15] Lucknow,
Railway
[16]
Moradabad[17]
Secunderabad,[18]
South
Vijayawada,
10. Central SCR 5803 Secunderabad
Hyderabad, Guntakal,
Railway
Guntur, Nanded
11. South
SECR 2447 Bilaspur
Bilaspur, Raipur

Name of
Route
Sl. the
length Headquarter
Abbr.
No Railway
(in
s
zone
Km)
East
Central
Railway
South
12. Eastern SER 2631 Kolkata
Railway
South
13. Western SWR 3177 Hubli
Railway

14.

Southern
SR
Railway

5098 Chennai

Divisions

Adra, Chakradharpur,
Kharagpur, Ranchi
Hubli,
Mysore

Bangalore,

Chennai,[19]
Tiruchirappalli,[20]
Madurai,[21] Palakkad,
[22]
Salem,[23]
Thiruvananthapuram[24
]

West
15. Central WCR 2965 Jabalpur
Railway
16.

Western
WR
Railway

6182 Mumbai

Jabalpur, Bhopal, Kota

Mumbai
Central,
Ratlam, Ahmedabad,
Rajkot,
Bhavnagar,
Vadodara

FEATURES OF MLR DONE IN CRWS

It as been estimated by work study that rehabilitation

work content is nearly 4 times that of normal POH .
Normal POH does not include major corrosion repairs
And takes about 2500 man-hours. Mid life rehabilitation
includes heavy corrosion repair and complete
refurbishing which takes about 10000 man ours . At
present this workshop is capable of undertaking any type
of ICF coach and BEML coach with ICF bogies.
Te underlying principle of MLR is to give As new
condition to the coach at its mid life i.ewhen it is 2-5
years of age.Unlike in POH,the coach is completely
stripped,heavy corroded ares attended to,fibre glass
tissue re-laid/re-painted , necessary modifications carried
out and new furnishing is provided. It can be seen that
wile corrosion repair is minimal attended to , during
POH , in MLR it is completely attended to.
Various
modifications
prscribed
by
Railway
Board/RDSO improving the performance of coaches,are
being implemented in this workshop.
Some of them are:Laying of FRP tissue on troug floor.
Provision of stainless steel inlays in lavatories.
Retro-fitment of air brakes
Pop riveting of mirror frames.
The roller bearing section as been improved and all
recommendations of COFMOW report have been
implemented.

What constitutes the CRWS ?

1. POCKET YARD
2. LIFTING SHOP

3. BOGEY SHOP
4. WHEEL SHOP
5. PCR SHOP
6. BODY SHOP
7. FURNISHING SHOP
8. CARPENTRY SHOP
9. PAINT SHOP
10. FINAL SHOP

POCKET YARD
The process of MLR (MID LIFE REHABILITAION)
starts with the entry of the railway coach in pocket yard.
In pocket yard the coach comes for inspection, whether it
is fit for the MLR or not. Several inspection are done for
this purpose.
Since only the coaches which is at their mid life (e.g. 1215 years) are selected for rehabilitation, for e.g. in 2014
the coaches built between 1998 to 2003 are select for
MLR.
In pocket yard the coaches are com by railway line
Bhopal station. Here they are kept for inspections.
Some inspection are as follows :
1. Inspection of the type of coach.
2. Inspection of the year of manufacturing of coach.
3. Inspection of the defects in coach.
4. Inspection of corrosion in coach.
5. Inspection of damaged part of coach.

These are some basic inspection done selecting the coach

for MLR.

LIFTING BAY
At the lifting bay, where it is simply lifted on a high
lifting machine.
In this shop coaches are lifted to remove bogies (the part
of coach contain wheels and brake) for repairs and
dummy bogies (temporary bogies with temporary
connections) are provided for internal movement within
the workshop.
In this shop the bogies are removed from coach by
disconnecting the centre pivot and two side bearer
provided in each bogie.( a coach has 2 bogies)
Examination and repair of under-frame including centre
pivot and side bearers are done in this shop.
The lifting shop is just behind the wheels and bogie sop
and also connected to the stripping and P.C.R shop and
carpentry shop. After the removal of the bogies they are
sent to bogie shop and then wheels and bearing are
removed from the bogie and shifted to wheel shop.
And the coach is shifted to STRIPPING and PCR SHOP
for further repair.

STRIPPING & PCR SHOP

As clear from its name STRIPPING and PCR SHOP ,
the work of stripping of the internal as well as external

part of coach body is done in this shop and also the

checking of corrosion affected area is done here.
In this shop internal components and fittings are stripped
off to get bare shell for corrosion repairs . Wall panels
and flooring is removed. Cutting of body side panels by
air plasma cutting is done in this shop.
In this shop the outer covering of coach body is removed
and the inner shell components are made visible for
corrosion treatment.
The coach body is cut by modern technique known as
Plasma Cutting for better and smooth cutting work
without affecting any other part. The cutting of side panel
is done in step by step process. First it is cut to height of
500mm from bottom to top and if symptoms of corrosion
are found above this.
Pre-inspection of coaches is most essential aspect for
identifying onset of corrosion. It must be done after
dismantling under slung components such as battery box,
vaccum cylinder, vaccum chamber , brake shaft and
electrical panel . All the pockets of under gear, head
stocks and old welding heads on sale bar surfaces must
be cleaned thoroughly of mud etc. to have clear visibility
of cracks and corrosion.
After the cutting of the body panel the internal fitting of
floor, lavatory, seats, births, doors, windows are done
here.
After this all the mechanical fitting are send to carpentry
shop for repair and the coach is sent to the body repair
shop for further repair of the coach body frame.

CARPENTRY SHOP

After the removal of all mechanical fitting in per shop

they come in carpentry shop for repair.
All internal mechanical fitting and furnishings including
berths and seats water tanks are repaired in this shop.
The main section in this shop are :
1. PLUMBING SECTION: In this section the all the
fitting used in plumbing work in coach is repaired like
water tank, housings, pipelines etc.
For repair to tank TIG WELDING is done. And leakage
tests is done for tanks at 0.35kg/sq.cm
2. DOOR SECTION: In this section the doors are
repaired by simple welding and which is removed from
the coach.
3. SHUTTER SECTION: In this section the shutters of
window is repaired by simple welding and which is
removed from the coach.
The equalizing device used for lifting window is also
repaired in this section.
4. CARPENTRY SECTION 1: In this section the old
seats and births are come and the old material is removed
and structure is also removed.
5. CARPENTRY SECTION 2: In this stop the
remoulding of seats and birth is done.
6. TRIMMING SECTION: In this section the furnishing
of carpentry is done.

BODY REPAIR SHOP

As clear from its name Body Repair Shop, the entire

body of coach shell is repaired here.
The entire coach body including members is subjected to
inspection and replacement of corroded members giving
necessary anti-corrosive treatments to the components
.RSP modification including provision of UIC Vestibules
are also done in this shop.
In this shop overall structure of coach body is repaired by
simple electrical welding, since main component of the
body shell is made up of iron and steel.
In this shop a large number of coaches are repaired
simultaneously. This shop is supported by SHELL
COMPONENT SHOP.

SHELL COMPONENT SHOP

The body repair shop does not manufactured any
required part that the reason shell component shop is set
up.
Component required for the fitment in the coach sell are
being manufactured from the raw material (mainly
corrosion resistant steel). It is a feeder shop for body
repair shop.

PAINT SHOP
In this shop the entire parts of the coaches get painted.

The coach shell is given a new look by complete painting

(A-SCHEDULE is undertaken). LETTERING WORK
on exterior as well as coach interior is done by screen
printing process. The work of laying FRP tissue on the
trough floor is also done in this sop. Air-brake retro
fitment work is done in this shop.
In this shop the paint work is done by hand or by the help
of the automatic painting machine. Here two-three layer
of paint along wit primer and anti-corrosive is applied on
the body of the coach.
A-SCHEDULED IS 8662/2004
1st day: As per need remove old paint wit scraper.
2nd day: Put primer on the old paint and on ten e panel
fitted and also to apply first coat of putty (primer IS
2074/1992), PUTTY IS 5083/1988.
3rd day: Second coat of putty and filler coat( filler IS
118/1983)
4th day: Coating of t anticorrosion paper.
5th day: Anti-corrosive rd oxide paint and first coat of the
primary paint (blue).
6th day: Second coat of the primary paint (blue).
7th day: Finishing of work.

FURNISING SHOP

Aesthetic look, comfort and safety are very much

essential for pleasant journey. Furnishing division takes
care of the above by furnishing the interior of the
coaches.
All passenger amenities fitting and internal components
(both mechanical and electrical) in the coach are
replaced/refitted. The work of PVC flooring and testing
of plumbing in lavatories are done in this shop.
As clear from its name all the finishing work is done in
this shop. All mechanical parts like seats ,births, doors,
windows and all other carpentry products are fitted in
this shop. More over the entry electrical fitting is done
and tested here.
Furnishing of coaches is done in stages , viz.
GRIT BLASTING, Painting in automatic paint booths ,
drying in ovens , lettering .
Flooring , wiring , paneling on side walls , window
fixing , partition paneling , floor moulding , lights & fans
fixing , seats , berths and racks fixing , air-conditioning
where required , brake fitment and buffer height
adjustment.

BOGIE SHOP

Bogies are the part on which the whole body of t coach is

mounted, it also help the coach to run on the track and
also help in stopping of coach.
In this bogie shop the bog are come from the lifting bay
and then the bogie is stripped of completely and the
wheels and bearing are shifted toward the wheel and
bearing shop respectively.
The running and brake gar provided in bogies are
completely stripped, cleaned , inspected and refitted.
The bogie frames are shot blasted. Bogies are modified
and provided wit brake gearing for bogie-mounted airbrake system.
The main work done in bogie shop is repairing of
structure of body it is over corroded than it is rejected
immediately.
In bogie shop went e bogie comes, it is visually inspected
by inspector than the dimension of bogie is checked by
gauges if the dimension is correct if it shift for further
repair otherwise the dimension is corrected by heating
and cutting and final repairing work is done by welding .
And then the bogie become reusable.

WHEEL
SHOP

&

BEARING

After removal of the wheel from the bogie shop, they

come in wheel shop. Here the inspection of wheel is
done by checking its diameter (upper limit 915mm and
lower 837mm below this the wheel is rejected).
If the wheel diameter is between upper and lower limit
its if further turned by CNC machine or lathe machine.
Here the ale of wheel is also repaired for this purpose
separate axle turning CNC and late is used.
After the repair of both wheels and axles they are again
assembled wit the help of the wheel press machine.
In this shop the bearing (roller bearings) of wheel is also
checked but not repaired. A separate shop inside wheel
shop is setup for checking of the bearing , several test
like magna flux test is done by magma flux testing
machine for checking the crack of less tan 2mm and U.V.
lamp is used to s crack clearly.
After all the inspection and repair the wheel bearing and
axle is assembled together and shifted toward the bogie
shop for being assembled in bogie.
In this shop the work of over all wheel assembly is done.
Here several machines are provided for repairing of
different component of the wheel and axle assembly.
If any components like wheel, axle, bearing etc are not
repaired they are also change here by the new one.

FINAL SHOP
This is the final shop were the MLR process of the coach
ends. In this shop fully furnished coach come through the
furnishing shop and bogie from bogie shop and both are

assembled here (during entire MLR process coach is

temporary set on dummy bogie).
And coach becomes ready for use again. The coach body
is lowered on overhauled bogies. Final adjustments as
tests/inspection of out-going coaches including NTXR
examination is undertaken in the final shop, which has
pit inspection facility.
In this shop several inspection on shop is done by visual
inspection if the coach complete the inspection or test
only than it is allow to go for further use otherwise it is
again return for repair in the respective shop where
defect is found like if paint is not proper it is further send
to paint sop for painting.
In this shop after the completion of inspection and
various test the coach is finally allow to go for further
use.
In other word we can say that it is the final stage of
M.L.R PROCESS where the COACH GET
REHABILITATED COMPLETELY and ALLOW TO
USE FOR SEVERAL MORE YEARS.