RAILWAY WAGON MANUFACTURING [3581]
TYPES OF WAGON:- (1) COVERED WAGON: Covered wagon is a wagon characterized by its closed construction (solid sides all the way up and roof) and by the safety it provides for the goods conveyed in it (possibility of padlocking and sealing). Closed Type Freight Wagons for transportation of all classes of General Goods, Food Grains, Bagged Cement etc. CONSTRUCTION OF COVERED WAGON:- A. SIDES: Sides are made up of side panels and side stanchions, which are attached to the underframe by crib angles/riveting strips /welding strips. They include top copings, doors, door fittings, label holders, rain protection angles above swing doors, door striking plates and anti bleeding device below the flap doors. B. ENDS: Ends are similar in construction to sides in that they consist of end panels, end stanchions, top copings and in some cases, intermediate copings. Attachment to the underframe is by means of end floor angles and through the stanchions. Covered wagons are provided with ventilators at the upper end of body ends. Corner stanchions connect the ends with the sides. C. ROOF: Roofs of covered wagons consist of roof sheets and carlines. Roof sheets are much thinner than the sheets used for the body sides and end panels. D. DOOR: Each side of the wagon is provided with door for manual unloading. The doors consist of swing doors at the top with label holder hinged to the angles on the sides and flap doors at the bottom, hinged at the bottom with Anti bleeding device.
COST ESTIMATION
Plant Capacity 12 Nos/Day
Land & Building (80000 sq.mt) Rs. 57.04 Cr
Plant & Machinery Rs. 85.81 Cr
Working Capital for 2 Months Rs. 97.06 Cr
Total Capital Investment Rs. 243.15 Cr
Rate of Return 16%
Break Even Point 65%
INTRODUCTION
(1) ACCORDING TO IT’S UNDER GEAR
(2) ACCORDING TO ITS UTILITY
TYPES OF WAGON
(1) COVERED WAGON
CONSTRUCTION OF COVERED WAGON
A. SIDES
B. ENDS
C. ROOF
D. DOOR
CLOSED TYPE – BCN, BCNA, BCNAHS, BCNHL
BCN
BCNA
BCNA-HS
BCCN/BCCNA/BCCNB
BCCN
(2) OPEN WAGON
A. SIDES
B. ENDS
C. DOORS
BOXN WAGON –
BOXNHA
BOXNHS
BOXN CR
BOXNLW
BOXNHL
(3) FLAT WAGON
CONSTRUCTION OF FLAT WAGON
A. ENDS
B. SIDE STANCHION
FLAT TYPE –
(4) TANK WAGON
TANK TYPE –
B.I.S. SPECIFICATION
PROCESS FLOW CHART
MANUFACTURING PROCESS FOR BOXNHL WAGON
DESCRIPTION ABOUT BOXHNL WAGON
DETAILS SALIENT FEATURES OF BOXNHL WAGON
3. BOGIE:-
4. BRAKE GEAR:-
5. RUNNING GEAR:-
STANDARD FEATURES OF ‘BOXNHL’ WAGON
(1) UNDER FRAME:
MAIN PARTS OF UNDERFRAME ARE:-
(2) CENTER SILL:
(3) SIDE BODY:
(4) END BODY:
(5) DOORS:
(6) BOGIE:
BOXHNL WAGON HAS CAS NUB BOGIE
FIGURE BOGIE GENERAL ARRANGEMENT FOR CASNUB
FIGURE BOGIE GENERAL ARRANGEMENT CASNUB
7. CENTRE BUFFER COUPLER
ADVANTAGES OF CBC:-
COUPLER BODY:
KNUCKLE:
(8) BRAKE SYSTEM
AIR BRAKE SYSTEM:
A) DISTRIBUTOR VALVE:
B) BRAKE CYLINDER:
C) CUT OFF ANGLE COCK:
D) DIRT COLLECTOR:
E) RESERVOIR:
F) METAL PIPES AND JOINTS:
G) SLACK ADJUSTER:
MAIN STEPS FOR FABRICATION
MAIN PROCESS
THE MAIN PROCESS HAS FOLLOWING STEPS ARE GIVEN BELOW
(1) CUTTING
(A). GUILLOTINING
THE FOLLOWING GUILLOTINE CLEARANCE SETTINGS ARE GIVEN
FOR GUIDANCE:-
(B) PLASMA CUTTING
(A) PLASMA CUTTING:-
(B) CNC PLASMA CUTTING:-
CUTTING GASES
(C) ABRASIVE CUT – OFF WHEELS
(D) ARC-AIR GOUGING
(E) POWDER CUTTING
(F) SLITTING
(G) COLD SAWING
(H) BLANKING AND PUNCHING
(I) DRILLING
(2) STRAGHTENING
STRAIGHTENING OF IRSM-44:
(3) PRESSING
(A) HYDRAULIC PRESS:-
(B) POWER HAMMER:-
(C) DROP HAMMER:-
(4) WELDING
(A) ARC WELDING:-
ARC WELDING CIRCUIT:-
DEFETS OF ARC WELDING:-
1. OVERLAP:-
2. UNDERCUT:-
3. POROSITY:-
4. SPATTER:-
5. CRATER:-
(B) GAS METAL ARC WELDING (GMAW)/MIG:-
DEFECTS OF MIG WELDING:-
1. OVERLAP:-
2. UNDERCUT:-
3. POROSITY:-
4. SPATTER:-
5. CRATER:-
IN A WAGON, VARIOUS PARTS ARE WELDED AS PRESCRIBED FOLLOWING
WELDING OF IRS M-44
(A) WELDING PROCESS
(B) WELD REPAIRS
(C) POST WELD CLEANING
(D) MECHANICAL CLEANING
(E) WELDING PROCEDURE:-
GENERAL PRECAUTIONS IN WELDING OF STAINLESS STEEL
WELDABILITY ISSUES:
PRECAUTIONS DURING WELDING:
PRECAUTIONS AFTER WELDING:
QUALITY REQUIREMENTS OF WELDING –
FABRICATION OF DIFFERENT PARTS
(1) CENTER SILL
3 FINISHED CENTER SILL SET
Z-SECTION
CENTER PART OF CENTRE SILL
END PART OF CENTRE SILL
FIXTURE OF CENTRE SILL
(2) UNDERFRAME
UNDER FRAME STRUCTURE
(3) BODY END
BODY END WITH VENTILATOR AND PRESSINGS
FIXTURE OF BODY END
(4) BODY SIDE
BODY SIDE FIXTURE
BODY SIDE
(5) DOORS
DOORS
(7) BRAKING SYSTEM
SLACK ADJUSTER AUXILIARY RESERVOIR
DISTRIBUTOR VALVE AND CONTROL BRAKE CYLINDER
LEVER ASSEMBLY PARTS EMPTY LOAD ADJUSTER
SHOE BRAKES
BRAKING PROCESS:-
(6) FINAL ASSEMBLY
PROCEDURE:-
A) REMOVAL:-
B) INSTALLATION:-
GENERAL DATA:-
(7) FINISHING (SHOT BLASTING)
(A) SURFACE PREPARATION
SHOT BLASTING CHAMBER
(B) PAINTING OF WAGON BODY AND UNSER FRAME
FOR STAINLESS STEEL
PRECAUTIONS TO BE TAKEN IN WORK AREA
PRECAUTIONS TO BE TAKEN IN STORAGE
PRECAUTIONS TO BE TAKEN IN STORAGE OF IRS: M 44 STEELS
(8) TESTING
(1) RADIOGRAPHY TEST (RT):-
(2) DI-PENETRATION TEST:-
(3) COMPRESSIVE STRENGTH TEST:-
SETUP FOR TEST
LOAD PROVIDING MACHINE
(4) WATER TESTING:-
WATER TESTING UNIT
(6) VISUAL INSPECTION:-
(7) BRAKING SYSTEM TEST:-
PRESSURE GENERATING UNIT
MARKET POSITION
FREIGHT CAN SPEED UP ECONOMIC GROWTH
SUPPLY CONSTRAINTS HIT INDIAN RAILWAYS’ INDUCTION
OF FREIGHT WAGONS
RAILWAY MINISTER SAYS INDIA FACING SHORTAGE OF WAGONS
INDIAN RAILWAYS INTENDS TO PURCHASE 38,000 WAGONS
SUPPLY CONSTRAINTS HIT INDIAN RAILWAYS’ INDUCTION OF FREIGHT WAGONS
RAILWAYS MULLS BUYING NEW WAGONS WORTH RS 9,000 CRORE
IN 3 YEARS
PLANT LAYOUT
MANUFACTURERS/SUPPLIERS OF RAILWAY WAGON
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF IRS M-44 SS SHEET
SUPPLIERS OF CRF SECTION
SUPPLIERS OF COMPLETE CAS NUB BOGIE ASSEMBLY
SUPPLIERS OF AIR BRAKE ASSEMBLY
SUPPLIERS OF WELDING ELECTRODES
SUPPLIERS OF PAINS MATERIALS
SUPPLIERS OF PLANT AND EQUIPMENTS
POWER PRESS
SHEARING MACHINE
ROLLING MACHINE
FLYPRESS
BENDING MACHINE
MECHANICAL PRESS
FORGING PRESSES
FORGING HAMMER
UNCOILING MACHINE
SHEET LAVELING MACHINE
PUNCHING PRESS
CNC PLASMA CUTTING MACHINE
MILLING MACHINE
CNC LATHE MACHINE
BOARING MACHINE
POWER HACKSAW
GRINDING MACHINE
PROJECTION WELDER
SEAM WELDING MACHINE
SPOT WELDING MACHINE
GAS WELDING EQUIPMENTS
MIG WELDING MACHINE
SUPPLIERS OF DRILLING, LATHE,TAPING MACHINES
EOT CRANE
POWER TRANSFORMER
ELECTRICAL PANEL
ELECTRIC MOTOR
COOLING TOWER
EFFULENT TREATMENT PLANT
AIR POLLUTION CONTROL EQUIPMENTS
AIR CONDITIONING EQUIPMENTS
AIR COMPRESSORS 160
PLATFORM WEIGHING MACHINE
MATERIAL HANDLING EQUIPMENTS
FIRE FIGHTING EQUIPMENTS
SHOT BLASTING MACHINE
JIGS AND FIXTURE
SUBMERSIBLE WATER PUMP
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
