LHB MAINTENANCE & ICF

CORROSION REPAIR IN CW/PER

SPRING SHOP
ACTIVITIES

VISHNU G
Trainee CMA
Group 9
Southern Railway
 History of CW/PER
• Founded in 1857 under Madras Railway
• Came under SR by amalgamating 3 railway companies in 1951
• CW/PER has 20 Major shops
• POH of AC coaches started in 1954
• Assisted ICF in furnishing till 1963
• POH of various types of AC and Non AC coaches are done.
• Rehabilitations of wagons, Conversion of BOXN to BOXNR
• First ever workshop of IR to convert vacuum brake system into
air brake system and developed first prototype of BOXNR
wagon (SS)
Organization Chart CW/PER
 Work Shop Activities
I. POH of Coaches
 Overhauling of BG AC and Non-AC Coaches
 Overhauling activities includes Heavy corrosion
repair of the under frame assemblies
 dismantling and reclamation of bogie assemblies
 repairs / replacement on account of furnishing train
lighting and painting of coaches.
 LHB Coaches are also given schedule attention
 Work Shop Activities
Shops involved in the overhauling of Coaches are:
1. Bogie Shop (BS)
2. Lifting Shop (LS)
3. Heavy Corrosion Repair Shop(HCR)
4. Ancillary Shop (ANC)
5. Water Tank Shop (WTS)
6. Brake Shop (BRK)
7. Draw and Buffing Gear Shop (DBG)
8. Furnishing Shop – Non AC (PCV)(FNA)
9. Furnishing Shop – Non AC (OCV) (FOC)
10. Furnishing Shop- AC(FAC)
11. Press shop(PS)
12. Train Lighting Works(TLW)
13. AC-Deluxe shop(DLX)
 Work Shop Activities
II. POH of Wagon
• Overhauling of Broad Gauge wagons of different types are being carried
out based on the light and heavy repairs. During the repair, the wagon is
stripped off. Assemblies and subassemblies are repaired or reclaimed or
replaced as the case may be, based on the service and utility factors. Sides
panels are retrofitted with Stainless steel materials. Then the wagon is
painted, tested and sent to traffic.
Shops/ Section involved in overhauling of Wagons are:
1. Wagon Repair – Lift and Body repair Shop (WRL)
2. Wagon Repair – Wheel and Bogie Shop (WRW)
3. Wagon Repair – Finishing Section (WRF)
4. Spring Shop (SP)
 Work Shop Activities
III Allied Activities
The following Shops / sections are involved in the allied activities in addition
to the above Core Activities
1. Mechanical Mill Wright Shop(MW)
2. New Machine Shop (NMS)
3. Chemical Metallurgical & Testing Lab
(CMTL)
4. Stores Depot (STO)
5. Planning section (PLG)
6. Progress section (PRG)
7. Personnel Branch (PB)
8. Basic Training Centre (BTC)
9. Inspection Department (INSP)
10. Road Transport Shop (RT)
11. Scrap Reclamation Centre (SRC)
12. Canteen (CTN)
13. Safety Cell (SAF)
14. Non-Personnel Branch (NPB)
15. Engineering Department(ENGD)
16. Drawing Office (DRG)
17. System Administration Team (SAT)
18. Health Department (HD)
19. Electrical Maintenance Shop (ELE)
CW/PER is accredited with
1. ISO 9001:2008
2. ISO 14001:2004 (4.4.6)
3. BS OHSAS 18001:2007 (4.4.6)
4. 5’S Policy
Maintenance of Coaches – Flow Chart
Lifting section
 Lifting Section
Main Activities
 Lifting, Lowering & Leveling
 IN CW/PER Coach body is lifted off the bogies by two over
head electric cranes of 25 T capacity. Each with suitably
designed lifting tackles
 The coach body id lifted from the lifting pads
 Before lifting dynamo belt, brake pool rod, bolster safety
strap, buffer and draw gear, lavatory chutes, battery box etc.
are removed
 Put the coach body on an old or condemned bogy or stand
 Special care should be given on buffer height, bolster
clearance, axle box spring height & thickness of wooden
packing and compensating rings
 DBG Section
 They follow the SS1 SS2 & SS3 schedule as per RDSO
 OEM instruction should be followed for the CBC
 Manufacturers of CBC are Escort(80%), Sandrof(10%) and Dellnear
 Balance draft gear is used to reduce longitudinal jerks
 RDSO 2011/CG03/Rev 01 Spec. is followed.
 SS3 schedule is done after 6 years and in this schedule all the components
should be removed and new components should be attached
 Bogie Shop
 After receiving, they first remove the bolster and release the
pressure
 Separate the springs and send it to the spring shop for
inspection
 Separate the wheels along with axles and send it to the wheel
shop
 Clean the bogie and inspect different parts, condemn the
failed parts and if the rest parts are in good condition leave it
with a little refurnishing(SS2)
 Assemble the required parts and inspect again
 CAMTECH manual is followed here.
 LHB Coaches

 Developed by Linke Hofmann Busch of Germany

 Manufactured in RCF, Kapurthala in India
 Design speed 160 KmpH, can go upto 200 KmpH
 Introduced in India in 2001
 First used in Delhi-Lucknow shatabdi Express
 Technology Transfer Agreement
 Why LHB ?

• Limitations of ICF
speed potential, heavy corrosion, poor riding comfort, less
weight, high noise level
• Made of stainless steel – less corrosion
• High capacity, low maintenance, better aesthetics
• Modular lighting, anti telescopic
 ICF Vs LHB
Sl No Attributes ICF LHB
1 Average speed less More than ICF
2 Safety safe More safe
3 Break system Thread break system Disc breaks
4 Relative Motion more less
5 Seating Capacity Less (3rd AC -64) More ( 3rd AC 72)
6 Sound Level 100 dB 60dB
7 Maintenance more less
8 Length with buffer 22296 mm 24000 mm
9 Length without buffer 21336 mm 23540 mm
10 Width 3245 mm 3030 mm
11 Life 25 Years 30 Years
SPRING SHOP ACTIVITIES
 Coil Spring
Coil spring is used in suspension system of both LHB
and ICF coaches along with dampers. Springs ensures
shock absorption thereby passenger comfort. In
CW/PER LHB&ICF coil springs are inspected and
proper maintenance is being done.
FLOW PROCESS FOR COIL SPRINGS OVERHAULING
PRE- INSPECTIONS
 The coil springs will arrive from body lifting
section check for any visible abnormalities – if it
is broken condemn it.
SOAKING IN BOSCH TANK
 Bosch tank is filled with 1:5 solution of Orion
331R(Cleaning Agent) and water which is kept at
80°C
 The springs are soaked in the tank for 4-6 hours
 This will remove paint grease, dirt and dust from
spring
Bosch tank and water jet cleaning
WATER JET CLEANING
 The springs are taken out from Bosch tank
 They are cleaned with high pressure water jet.
 This will remove the all dissolved impurities and the excess
solution
 The springs are dried then.
SHOT PEENING
 The dried springs are fed into shot peening machine.
 Shot peening is a cold working process in which the material
surface is peened to induce compressive stresses by
bombarding spherical metallic balls into the spring
 This is done to improve fatigue life, perfomance
 It also reduces maintenance and premature failure
https://www.youtube.com/watch?v=AgPsxoZnEa0&t=28s
NUMBER NOTING AND VISUAL INSPECTION
After shot peening we visually inspect the
springs and not down their numbers
In this process we check for any visual
defects like tip broken, slant, dent and notch
 SPRING DEFECTS

https://drive.google.com/file/d/1eJ4PVMgxCj9YpMnQNXmfGhI0kR_cn9Rv/view?usp=sharing
WHAT IS SPRING NUMBER ?

CM ICF 01 13 B01 R 75

CM- composition, here chromium & manganese

ICF – Manufacturer (RSK,ICF,GBD,FSP,FSK)
01 – Month of mfg.
13 – Year of mfg.
B01 – Spring type
R 75 – Batch code
 SPRING TYPES
Spring No Type
A 01 Axle (13T) Non AC
A 03 Axle (16T) AC
A 10 Axle (VPH)
A 09 Axle(power car)
D 02 Axle (LR, VPU)
B 01 Bolster(13T) Non AC
B 03 Bolster(16T) AC
B 15/ B16 Bolster (VPH) - Nested
B 11 Bolster (power car ) - nested
D 54 Bolster (LR,VPU)

Note : In visual inspection check for RSK B01 L series which withdrawn from service by
RDSO due to continuous breaking
MAGNETIC PARTICLE INSPECTION
• A ferromagnetic test specimen is magnetized with a strong
magnetic field created by a magnet or special equipment
• If the specimen has a discontinuity then it will interrupt the
magnetic field flowing through the specimen and leakage field
will occur.
• Finely milled magnetic particles coated with a
fluorescent dye pigment are applied to the specimen
• These particles are attracted to the leakage fields
and will cluster to form an indication directly over
the discontinuity
• This indication can be visually detected under proper
lighting conditions
MAGNETIC PARTICLE INSPECTION (IS 3703 : 2004)
 Check MPI sensitivity using Keto’s ring
 Magnetic particle bath solution using water soluble UV light
fluorescent powder of 1% strength is prepared and
concentration is checked weekly
 Place the pre cleaned spring on steady roller
 Clamp the spring
 Select mode of magnetization (Headshot/Central conductor)
 Magnetize the spring by pressing “Mag” button
 Spray the magnetic particle solution all over the spring
 Declamp the coil spring
 Inspect coil spring under UV light for any cracks
 Demag and declamp the coil spring
MPI machine Dash board for MPI Coil spring under inspection
 Defective springs are condemned and stacked
 Passed springs are allowed into service
 Results are recorded as per the record
SENSITIVITY TEST FOR MPI ( KETOS RING)
 Ketos ring is a ring shaped component 127 mm in dia 22.22
mm thick with a central hole of 31.75 mm dia. It comprises of
12 holes of 1.77mm dia at different depths from the outer
periphery. This Ketos ring is used to assess the sensitivity of
MPI
 Slip the copper bar of dia 29.4 to 31.7 mm and length to 40 to
60 mm in the central hole of the ketos ring
 Clamp the copper bar (Central Conductor) between the
headstock and tail stock
 Slide the Ketos ring into the middle of the bar
 Spray the suspension medium and press “mag” button
 https://www.youtube.com/watch?v=kYWeTd4ePiw

https://drive.google.com/file/d/1LiR3b2MkPY1w7lpFZu3noBmSyUluDxRk/view?usp=sharing
 Record the visible indications (minimum 3 depths should be
detectable) ie, sensitivity is 3mm.
 Press demag and the sensitivity is noted.
MAGNETIC PARTICLE BATH PREPARATION AND
CONCENTRATION CHECK
 Dissolve 250g of water soluble fluorescent magnetic particles
(grade RWH 223) in 25L of water in the tank provided with
MPI machine
 Agitate it well to ensure uniform particle suspension
 From that take 100mL solution in a centrifuge tube
 Place the centrifuge tube in its stand and allow the
suspension to settle for 30 minutes in a vibration free location
 Observe the level of suspended particles graduations on the
tube
 If a contaminant layer is present subtract from the total level
to obtain magnetic particle concentration
 Illuminate the centrifuge tube and suspension with UV light
 It is recommended to maintain a range of 0.2 – 0.7mL in
100mL sample.
LOAD TSETING
 Each spring should be subjected to incremental load up to the
figure indicated in the table below
 The load should be maintained for a period of 2 minutes
 After which the corresponding height of spring under load is
determined.
 According to the load test height the looping is done
LOAD TEST & GROUPING
PAINTING
 After load deflection test, the acceptable springs should be
given one coat of Red Oxide Zinc Chromate primer to IS:2074
to a minimum DFT of 50 microns.
 A coat of Black Japan Type-B to IS:341 to a minimum DFT to
35 microns should follow the primer coat to have better
abrasion resistance and corrosion resistance.
 Then the springs have to be painted with 50 mm wide vertical
stripes at three locations, equispaced on the circumference
using different colours of paints to IS:8662 as given below

Spring group Colour code

A Yellow
B Oxford Blue
C Green
 All the springs should be grouped in three groups as
shown in table above, depending upon their
deflection under test load.
 For pairing, springs should be selected from the
same group.
 Height under test load should be painted on all
springs to enable selection of springs.
 ERS- ALLP Passenger,
Pathimoonnu Kannara bridge, Thumboli Rly. Station (TMPY),
Kollam – Senkottai Route, MDU/SR SR