Industrial Training at Indian Railway, Howrah Division

21st - 27th September 2024

Ten students of ME/ EEE Department along with faculty coordinator Dr. Saket Kumar (Assistant Professor, ME Department) Dronacharya Group of Institutions, Greater Noida participated in a training program organized by the Indian Railways at various locations of Coaching Depot of the Eastern Railway, Howrah Division, Kolkata from 21^st -27^th September 2024.

The main objectives of the training program were:

• To bridge the gap between academic knowledge and practical application.
• To provide an in-depth understanding of the mechanical systems used in Indian Railways.
• To familiarize students with the technical aspects of locomotive maintenance and repair.
• To encourage innovative thinking by exposing students to real-world engineering problems.

The Mechanical Workshop in the Howrah Division is one of the oldest and most prominent railway workshops in India. It handles the maintenance and overhaul of locomotives, passenger coaches and freight wagons. The workshop is equipped with state-of-the-art machinery and tools, and it adheres to strict safety and quality standards. It is also known for its contribution to research and innovation in the railway industry.

The departments included:

▪ Locomotive Maintenance Unit: Students were trained in the maintenance procedures of both diesel and electric locomotives. They learned about engine components, fuel systems, transmission mechanisms, and the electrical systems essential for locomotive operations.

▪ Coach Maintenance and Overhaul: This department provided exposure to the repair and refurbishment of passenger coaches. Students observed how worn-out parts of coaches were replaced or repaired to ensure safety and comfort for passengers.

▪ Freight Wagon Repair Unit: Students were given an understanding of the critical role of freight wagons in transporting goods across the country. They witnessed the inspection, servicing, and repair of wagons, including bogie systems, braking mechanisms, and coupling arrangements.

▪ Machine Shop: A highlight of the training, the students were introduced to the sophisticated machinery used for precision manufacturing and repair of locomotive parts, including lathes, milling machines, CNC machines, and grinding tools.

Sealdah Depot Maintenance practice of ICF coaches at NCC:

Students got to know the different types of coaches manufactured and designed in Indian Railway by RDSO. Along with a detailed explanation of different coaches and general terminology used in coaches from design to manufacture to maintenance were explained by higher officials. Students also got knowledge about the whole maintenance setup and its necessity during on sight visit at Sealdah depot. The maintenance of train is done in trip schedule and each part (component/ system) of it is checked and replaced if required for intensive Supervision and Quality Control. Different wheel cracks and disruptions are being detected by the visual inspection or by hammering sound detection method.

Rolling Stock Inventory of Indian railways:

Maintenance, Repair and Certification of the entire Rolling Stock Inventory of Indian railways comprising planning of maintenance activities including placement of rakes in Pit Lines, balancing of rake occupation in Pit Lines, Detachment of Coaches and Wagons for Scheduled maintenance activities like POH and IOH / ROH, etc. Preventive Maintenance activities of Coaches and Wagons in Pit Lines and Yards. (Examination and rectification of each and every component, for any failures, abnormalities and unsafe condition, which may endanger the safety of the train by Analysis and reporting of component failures, Certification of the entire train for its overall safety till the train returns to the originating station, Maintenance of all registers with respect to train service, Issuance of Brake Power Certificate, Prevention and analysis of enroute failures like train parting, brake binding, hot axle, etc . Primary Maintenance - Carried out for the Train as a whole Need - Mandatory for every train. Place - Pit Lines in Coaching yards. Works - Safety, Amenity, Electrical, A/C, Internal & External cleaning and Brake power testing with certification. Time - Minimum 6 Hrs in Pit lines. Inspection, testing and attention of all the vital safety components both visually and using inspection tools and gauges to ensure safety of the whole train.

Naihati Depot for Welding simulator practice:

Naihati Depot for Welding simulator practice and Major crane operations for maintenance This day was dedicated for understanding about wheel manufacturing, wheel specifications, wheel maintenance, and also excellent welding simulator. Student got to know about the basic wheel types and their different diameters and their coupling and bearings attached. CTRB (Cartridge Tapered Roller Bearing) which is used in the wheel of train for rotating motion. They use a software-based system for detecting the components being attached successfully and are ready to perform respective operation. Welding is also done at the same site, there is a welding simulator too for determining welding accuracy for students as well as professionals

Naihati Depot for Wheel and major maintenance work:

A visit to the Naihati Depot for wheel and major maintenance work on Day 4 offered students an excellent opportunity to understand the technical and practical aspects of vehicle maintenance.

VANDE BHARAT maintenance at Jhil siding depot: 

The day was very special and exciting as student’s got the opportunity to understand the whole systems that are implemented in VANDE BHARAT. History of Vande Bharat, it's launching and different types, were briefly explained. It's self-propelling system was explained and they got to know about the electrical systems, motors, driver-tailor coach, line traction converter and many other important components of it that makes it "VANDE BHARAT". After that, train's anticollision system was explained to them, and what the ways are by which Indian railway is overcoming the collisions using different efficient couplings, and secured systems. Then, students got a chance to enter in the pilot's cabin to see the functional operations that are really very easy to control for professionals. And are fully sensors and transducer-based systems embedded.

Key Learning and Outcomes:

During the program, the students gained the following knowledge and skills:

• Practical Exposure to Railway Technology: They gained firsthand experience in understanding how theoretical concepts like thermodynamics, fluid mechanics, material science, and manufacturing processes are applied in a practical setting.
• Problem-Solving Skills: Students were encouraged to solve real-time technical issues encountered during locomotive and coach maintenance, improving their analytical and troubleshooting skills.
• Safety Practices: The workshop emphasized the importance of adhering to safety protocols, including the use of personal protective equipment (PPE) and understanding emergency procedures, fostering a culture of safety in mechanical engineering practices.
• Understanding of Large-Scale Operations: The students developed an appreciation for the complexity of managing large-scale mechanical operations in a high-stakes environment like Indian Railways.

The students had the opportunity to interact with highly experienced railway engineers and technicians. These professionals shared insights on:

• Challenges faced in railway maintenance and the solutions developed over time.
• The integration of new technologies such as condition-based maintenance and predictive analytics for better operational efficiency.
• Career opportunities in the Indian Railways and other sectors related to Mechanical engineering.

The participation of mechanical engineering students in the Indian Railways training program at the Mechanical Workshop in Howrah Division was highly beneficial. The program successfully met its objectives by providing the students with valuable industry exposure, equipping them with practical knowledge, and enhancing their problem-solving abilities. Such programs play a crucial role in shaping future engineers by helping them understand the demands of the industry and preparing them to contribute effectively to it.

List of students who attended the training