PROJECT REPORT ON VOCATIONAL TRAINING

BURN STANDARD COMPANY LIMTED

NAME-SURYA SHANKAR ROYMechanical engineering4th year, 7th semesterCOLLEGE- dr.sudhir Chandra sur degree engineering collegeTRAINING PERIOD-29TH JUNE TO 29TH JULY.

DATE DEPARTMENT SIGNATURE

29/06/15-06/07/15

WAGON DEPTT.

15/07/15-22/07/15

FOUNDRY SHOP

07/07/15-14/07/15

E.W DEPTT./ MAINTAINENCE

DEPTT.

25/07/15-26/07/15

T&F, R.M.S, CTR DEPTT.

07/07/15 COMMERCIAL DEPTT.

28/07/15 COUPLER DEPTT.

24/07/15 PURCHASE AND STORE DEPTT.

27/07/15 ACCOUNTS DEPTT.

29/07/15 PERSONNEL DEPTT.

TRAINING SEHEDULE

PREFACEThe report is prepared on the basis of four weeks Vocational training (from 16th

June to 15th July, 2015)

At the BURN STANDARD COMPANY LTD., HOWRAH.

The program was arranged by the Department of Training and Placement,

DR.SUDHIR CHANDRA SUR DEGREE ENGINEERING COLLEGE, DUM DUM.

The report has been made by the knowledge and experience gathered during the

training scheduled at the factory premises’ careful and devotional effort has been

given to provide an overall feature of different sections and the activities toward

the common goal of the factory.

Fortunately, this volume has been possible to create because the great

contribution of all the chief member, worker & co-worker of the factory premises.

Finally, I would like express my gratitude to all incorporations & helping hands

therefore making our training possible.

THANKING YOU

HISTORY OF BSCLBurn Standard Company Ltd., is one of the oldest and a leading wagon builder in India. The wagon building activities are carried out at two Engineering Units at Howrah and Burnpur situated in West Bengal, India.

During the early days, Burn & Company undertook building and contracting work. Subsequently in the 50s of the last century, it ventured into the field of Railway Engineering, altogether new development in the country's economy. With the rapid expansion of Railways, Burn & Company started manufacturing Railway rolling stock at Howrah to cater to the increasing demand. The Burnpur works, earlier Indian Standard Wagon Ltd., Burnpur, - since its early days (from 1920) developed excellence in manufacturing Railway wagons, forged components, springs etc.

Several thousand wagons covering all major designs have been manufactured and supplied to Indian Railways and other Industrial Customers.

Apart from supplies to Indian Railways, the Company also manufactures and supplies special purpose wagons to various core sectors like power, steel plants in India.

The Company has supplied special purpose wagons fitted with Air Fluidising System for bulk movement and quick unloading of Alumina powder to M/s. National Aluminium Co. (NALCO). It has also supplied sophisticated Bottom Discharge Wagons to National Thermal Power Corporation (NTPC), New Delhi for their various plants in the country.

Products and services

Railway wagons: tanker, hopper, flat Casnub bogies Couplers and Draft Gears Steel Castings, Pressings, Forgings Bridge

Girders, Structurals, Sleepers, Points and Crossings, Wagon Components

Wagon refurbishment o Burn Standard India renovated SLC Type for the CLC system in

Kolkata in 1980s. Ash/coal plant construction

WAGON DEPARTMENT

Goods wagons or freight wagons are unpowered railway vehicles that are used for

the transportation of cargo. A variety of wagon types are in use to handle different

types of goods, but all goods wagons in a regional network typically have

standardized couplers and other fittings, such as hoses for air brakes allowing

different wagon types to be assembled into trains. The wagons are also equipped

with an auxiliary storage tank for storing compressed air sent from the engine

which is to be used for the purpose of braking. A network of pipes below the

wagon helps in passing this air to the brakes. For tracking and identification

purposes, goods wagons are generally assigned an identifier, typically a UIC

wagon number, or in North America, a company reporting mark plus a company

specific serial number. The region to which the wagon is assigned is also

mentioned on the wagon body. The company which has made the wagon, its seal

is also stamped on the wagon body. Then the wagon is painted.

Although different types of wagons are made, the two types of wagons mostly

manufactured is the BO-XN-HL wagon (which is an open type wagon) and the

Boxcar(closed type wagon).

We mainly had the opportunity to look at the BO-XN-HL wagon.

VISION & MISSION

VISIONTo be a leading manufacturer of Wagons and Castings and to develop the Company as a lead player.

MISSION

To enhance core sector performance and diversify into non-core sector activities as per Road Map envisaged in the Corporate Plan.

To focus on modernization / up-gradation of manufacturing facilities and to update product design, manufacturing technology and production facilities to manufacture wagons, bogies and couplers as per international standard.

Collaborative technological tie ups with domestic/international partners for up-gradation and diversification of business.

To come out of BIFR with implemented financial restructuring and support, as approved by the GOI coupled with achieving ambitious physical and financial targets of the Company.

Production Units & ProductsEngineering Unit, Howrah Works 1.Wagons

- BOSTHSM2- BOXNHL- BRN 22.9- BOBRNHSM12.Steel bridge girders and steel structures

Steel Foundry Unit, Howrah Works

- Steel Casnub bogies for wagons- Couplers & Draft Gears for wagons- Other Bogie components

Engineering Unit, Burnpur Works Wagons- BOBRNHSM1- BOBSN- BOXNHL

7. ANALYSIS:

STRENGTHS:

# Strategically located in wagon industry cluster.# In house facility to manufacture bogies and couplers critical for wagon production.# Developing couplers to new 70-BD design.# Surplus land which can be used for business development.# Strong brand name in steel fabrication and bridge girder fabrication.# Enhanced and versatile capacity of steel foundry after commissioning of High Pressure molding machine and no bake system of molding.WEAKNESSES:# Shortage of Technically competent executives# Indiscipline environment# Dilapidated Physical Infrastructure# Inadequate machinery and plant# Constraint of Working capital# Demoralized employeesOPPORTUNITIESa) Rise in demand of wagons from Railways and non-Railway customers on account of Dedicated Freight corridors.b) Demand in ash handling plants and structural fabrication due to stress on development of infrastructure.c) Increased demand of rehabilitation of wagons and refurbishing of coachesTHREATSa) Increased competition from other wagon builders.b) Discontinuance of free supply items by Indian Railways.c) Rise in cost of inputs.d) Very low margin due to release of order on L1 price discovered through tender.e) Reduction in wagon demands due to further slump in economy.

8. BRIEF ON CORPORATE PLAN:SHORT TERM: (up to 5 years):# To improve the productivity of the labour force.# Dispose off idle, obsolete assets.# Strengthen and enhance the capacity of foundry.# To get the license to produce couplers to 70-BD specification and meet the Indian Railways requirement.# Increase fabrication of steel structural.# To continue and grow the ash handling project business.

LONG TERM: (beyond 5 years):# To procure orders from non-Railway customers, to reduce dependence on Railways.# To fabricate Rail vehicles like Over Head equipment cars etc.# To capture market for components for wagons and coaches.# Tie up with technology partners to have access to new technologies.# To go for fresh recruitment of professionals to replace retiring executives and to take responsibility for enhanced activities.# To come out of BIFR.

SALIENT FEATURES FOR ‘BOXN’ WAGON

Sl. no. Particulars Description1. Estimated tare weight 22.47T2. Payload 58.81T3. Gross load 81.28T4. Axle load 20.32T5. Ratio of payload to tare weight 2.72T6. Truck load density (gross) 7.59T/m7. Floor area 20.87 sq. m8. Volumetric capacity 56.29 cubic m9. Overall width 3200 mm10. Inside width 2950 m11. Journal center 2260 mm12. Length of center buffer faces (NT) 10713 mm13. Length over head stock 9784 mm14. Bogie center’s 6524 mm15. Wheel diameters on trend (new/condemning) 1000 mm / 906 mm16. Wheel base 2000(+ -) 5 mm17. Height of CBC from rail level 1105 mm18. Distance between side bearers 1474 mm19. Type of side bearers Roller type20. Type of Centre pivot IRS spherical21. Type of brake beam Unit type fabricates brake beam22. Suspension details Long travel helical spring

suspension23. Type of roller bearing Std. AAR CTRB suitable for

152.4*276.4mm(6’’*11’’wide jaw)

24. Type of bogie CASNUB 22W

25. ‘A’ dimension 70(+2 -0) MM

Details salient features of BOXN Wagon:-1. No. of doors in BOXN wagon – 2 on each sides (on both

ends)2. DRAW AND BUFFING GEAR:-

High capacity, high friction gear used. High tensile straight CBC used. CBC coupler working capacity – 120 ton. Hauling capacity in 1:100.In up gradient – 9000 ton

3. BOGIE:- CASNUB bogie used. Axle load capacity – 22.9 ton. Secondary suspension, helical aping is used. UIC spherical type Centre pivot fixed [except 22W, 22W(R)]. Fit for 90 mph, 100 mph for HS. Maintenance cost is less. Metal bonded constant contact rubber pad side bearer used.

4. BRAKE GEAR:- Single pipe air brake system. SAB, empty load device used. Clearance between wheel and brake is maintains through SAB. No. of brake beam – 4. No. of brake block – 8.

5. RUNNING GEAR :- Axle load – 22.9 ton. Axle bearing – CTRB. New wheel dia. – 1000 ton. Condemning dia. – 906 mm. Journal Centre – 2260 mm. Dia. of journal – 144.5 mm.

BOX NHL WAGON

STANDRARD FEATURES OF ‘BOXNHL’ WAGON

SL. NO.

PARTICULARS BOXNHL

1. Length of overhead stock (mm) 100342. Length over couplers (mm) 109363. Length inside (mm) 100344. Width inside / width overall (mm) 3022/32505. Height inside/height (max) from RL. 2028/33016. Bogie centers (mm) 66907. Journal length*dia. (mm) 144*2788. Journal centers (mm) 22609. Wheel dia. on thread(New/worm) (mm) 100096010. Height of C.B.C. from R.L. (mm) 110511. C.G. from R.L. (empty) (m)12. C.G. from R.L. (loaded) (m)13. Floor area (Sq.) 30.3214. Cubic capacity (CU.M.) 61.0515. Maximum axle load (tone) 22.916. Tare weight (tone) 20.617. Pay load (tone) 71.018. Gross load (Pay Tare) (tone) 91.619. Ratio gross load/tare 4.4520. Ratio(Pay load to tare) 3.4521. Track loading density(tones/meter) 8.3522. No. of wagons per train 5823. Brake system Air Brake24. Coupler C.B.C25. Bearing R.B.26. Maximum Speed (loaded)

(empty)75 mph100 mph

A ‘BOX NHL’ WAGON:

The Bogie open wagon was designed at 22.8t axle and 250mm

The BO-XN-HL wagon. The wagon is manufactured by using stainless steel around the rolled sections.

CASNUB BOGIECASNUB BOGIE: CASNUB BOGIE means Cast Steel Bogie equipment with three sets of springs. (i).Outer spring, (ii).Snubber spring, (iii).Inner spring.

Bogie comprises of two cast steel side frames and a floating bolster.

The bolster is supported on the side frame through two nests of spring, which also incorporate a load proportional friction damping the side frames are connected by a fabricated mild steel spring plank to maintain the sequence of the bogie .There are two sets of wheels for each side frame.

BOGIE COMPONENTS1. Side frames wide friction plates.

2. Spring plank.

3. Friction shoes.

4. Load bearing spring.

5. Center pivot top & bottom.

6. Bolster pivot pin.

7. Side frame key bolt, nut, spring washer& split pin.

8. Elastomeric pads.

9. Bogie brake gear.

BOGIE GENERAL ARRANGEMENT FOR CASNUB

a) Bolster:

(I). Pocket Slope Liner: Change liner if thickness less than 5mm.

(II).Rotation Stop Plugs: Provide liner (thickness to suit) if dimensions less than

514mm.

(III). Inner Column Gibb: Provide liner (thickness to suit) if dimensions more than

142mm.

(IV). Land Surface: Provide liner (thickness to suit) if dimensions less than

442mm.

(V). Outer Column Gibb: Renew by welding if dimensions more than 241mm.

b) Side Frame:

(i) Column Friction Liner: Change liner if dimensions more than 445mm.

(ii) Column Side: Provide liner (thickness to suit) if dimensions less than 209mm.

(iii) Anti Rotation Plugs: Provide liner (thickness to suit) if dimensions more than

526mm.

(iv) Key Seat to Pedestal 22W: Provide liner (thickness to suit) if dimensions more

than 276mm, 149.

(v) Crown Roof 22W (M): Provide liner (thickness to suit) if dimensions more

than 321mm

(vi.) Crown Roof 22 NL: Provide liner (thickness to suit) if dimensions more than

326mm.

(vii.) Pedestal Crown Sides: Renew by welding if dimensions less than 147mm.

(viii.) Pedestal Jaw 22 W: Provide liner (thickness to suit) if dimensions more than

275mm.

(ix.) Pedestal Jaw 22 W (M): Provide liner (thickness to suit) if dimensions more

than 283mm.

(x.) Pedestal Jaw 22 NL-S: Provide liner (thickness to suit) if dimensions more

than 195mm.

(xi.) Pedestal Jaw 22 NL-L: Provide liner (thickness to suit) if dimensions more

than 241mm.

(VI.)Pedestal Sides 22 W: Provide liner (thickness to suit) if dimensions more than

102mm.

(VII).Pedestal Sides 22 W (M): Provide liner (thickness to suit) if dimensions

more than 195mm.

(VIII).Pedestal Sides 22 NL: Provide liner (thickness to suit) if dimensions more

than 178mm.

c) Wedge:

i. Slope Surface: Renew by welding if dimensions less than 7mm.

ii. Vertical Surface: if vertical surface from the centre line of spigot less than

56mm, and then provide liner of 6mm thickness.

d) Centre Pivot (Bottom):

i. Vertical Side 22 W: Renew by welding if wear more than 4mm.

ii. Vertical Side 22 W (M): Renew by welding if wear more than 3mm.

iii. Vertical Side 22 W NL: Renew by welding if wear more than 3mm.

iv. Seat 22 W: Renew by welding if wear more than 3mm.

v. Seat 22 W (M): Renew by welding if wear more than 3mm.

vi. Seat 22 W NL: Renew by welding if wear more than 3mm.

e) Coil Spring:

i. Outer: Group and use in seats. Replace if free height lass than 245mm.

ii. Inner: Group and use in seats. Replace if free height lass than 247mm.

iii. Snubber: Group and use in seats. Replace if free height lass than 279mm.

iv. f) Bogie Brake Gear:

v. Pins and Bushes: change if clearance is more than 1.5mm.

vi.

CENTRE BUFFER COUPLERCBC is combines unit of Draw and buffer bearing, located at the Centre of the body head stock.

Used as draw Gear. Used to transmit buffing force.

ADVANTAGES OF CBC:- Coupler and buffing gear both are located at the Centre of wagon. Hauling capacity increased. Maintenance cost is less than Conventional Draw gear. Hauling capacity of CBC – 7000T to 9000T

TYPES OF CBC ON THE BASIS OF OPERATION:

(1) Transition type CBC (2) Straight type CBC

cOUPLER BODY:

i. Coupler headii. Coupler tail

iii. Coupler guard armiv. Coupler lock chamber

KNUCKLE:

i. Knuckle noseii. Knuckle lock face

iii. Knuckle front faceiv. Knuckle pin

STRIKER CASTING

STRIKER CASTING WEAR PLATE

LOCKING PIECE

ROTARY LEVER ASSEMBLY

CBC OPERATING HANDLE

CBC OPERATING HANDLE BRACKET

CBC OPERATING HANDLE WEAR PIECE

YOKE PIN SUPPORT PLATE

YOKE SUPPORT PLATE

TRANSITION COUPLING

FRONT FOLLOWER

BACK STOPPER

YOKE, YOKE PIN

DRAFT GEAR

BEARING PIECE [Size 16*16*270 mm (Modified) with 16*16*210mm

PARTS OF A WAGONMajor parts of a wagon include the following:-

1). Under Frame

2).Side Body

3).End Body

4).Door

5).Bogie, Wheels, Axle and Bearings

6).Brake equipment and piping

ASSEMBLY WORK PROCESS OF A WAGON 1).The most vital part of the wagon is the under frame. The under frame is made up of 29 subparts. The under frame is put together by holding it in a fixture. The major components of the under frame are the following:-

Center Sill(1) Sole Bar(2) Headstock (2).The head stock has housing for the coupler. Bolster (4).The bolster carries the load of the wagon and the wagon is placed on the

CPT (Center pivot Top) and screwed. Cross Bar and Spatial Cross bars(2 on each side of a bolster) Crib angle. It has an angle of almost 90 degrees and bent and is welded on top of the

head stock and sides. The side and end body of the wagon will rest there. Other components include Proplate, Stringers for support.

All these components are put together by welding and by hot bolting. The one end has the striker casting fitted to it and riveted. Behind striker casting back stop is fitted and behind back stop diaphragm base plate is fitted. The inner side of the under frame is welded using MMAW while the outer side of the under frame is made by SAW (Submerged Arc Welding).

2).The side body of the wagon is the outer frame which is fitted at the two sides of the wagon. Sides are made up of side panels and side stanchions which are attached to the crib angles, riveting strips or hot bolting.

3).The end body is similar to that of the side body in the sense that they consist of end panels, end stanchions etc. Corner connectives connect the ends of the wagon with the sides.

4). There are 2 doors on each side of the wagon. They are hinged at the bottom and they can be unloaded manually.

WAGON MANIPULATOR: The wagon manipulator is used for putting the wagon together by clamping the different parts of the wagon together, making it easier to carry out welding operations. The manipulator can be turned using motors and the wagon body set at different angles.

The wagons are moved around to the different parts of the bay using EOT cranes.

Almost all wagons are made up of mild steel using GMAW (For MS, CO2 gas is used).

If the wagons have to be protected from corrosion, then Stainless steel is used (For SS, Argon gas is used).

The different parts of the wagon are made using machine tools in the bay such as gang drilling machines, shearing machines, radial drilling machines, plate bending machine, hydraulic and mechanical squeezing machine etc.

The wagon is then mounted on the bogie sets. After shot blasting the wagon structure, brakes are fitted. The wagon is then painted, lettered and inspected before dispatching them.

5). Air Brake System:

a) Distributor Valve:

i. D.V.: Test on SWTR.

ii. D.V. Isolating Cock" Examine operation.

iii. D.V. Release Valve: Examine operation.

iv. D.V. P4AG Filter: Clean.

b) Brake Cylinder:

i. Filters of escorts and RPIL make: Clean.

ii. Brake Cylinder of Gresham and WSF Make: Lubricate

c) Cut off Angle Cock:

i. Angle cock: Examine and lubricate.

ii. Rubber Seals: Change.

d) Dirt Collector:

i. Dirt Collector: Clean.

ii. Sealing Ring: Change.

e) Reservoir:

i. AR & CR: Drain.

ii. Sealing Ring: Change.

Gaskets (MU Washer): Change

d) Dirt Collector:

iii. Dirt Collector: Clean.

iv. Sealing Ring: Change.

e) Reservoir:

iii. AR & CR: Drain.

iv. Sealing Ring: Change.

v. Gaskets (MU Washer): Change.

f) Metal Pipes and Joints:

i. Pipes and Joints: Examine leakage and repair.

ii. Seals (20mm and 32mm pipe): Change.

g) Slack Adjuster:

i. Slack Adjuster: Test Functioning, repair if required.

ii. A Dimension: Adjust.

iii. M20 Anchor Pin Nut: Ensure securing by welding to pin.

h) Air Brake System:

i. Brake System: Test on SWTR as per procedure.

Brake Block: Ensure standard key split pin and all new brake block.

6.) Wheel Axle and Bearing

a) Axle:

i. Ultrasonic Testing: To be carried out at every ROH and reject if fails.

ii. Deep Notches due to grating of Pull Rod: Reject if depth is more than 5mm.

iii. Axle and Holes: Clean and lubricate in case end cover is opened.

b) Wheel:

i. Tread Profile: Check with tyre defect gauge.

ii. Height of Flange: If height more than 31mm do not use in ROH.

iii. Smooth Flange: If flange not completely smooth in region 'A', then do not

use in ROH.

c) Bearings:

i. Cup: Rotate the bearing for unusual sound. Check cup for crack/chipping.

ii. Seal: Check seal for external damage and dent.

iii. Backing Ring: Check backing ring for looseness and vent fitting on backing

ring with vent hole (the vent fitting should be intact or the vent hole should

be plugged).

iv. Locking Plate: Use new looking plate whenever end cover is opened.

v. Axle End Cap screw: Clean and lubricate in case end cover is opened.

vi. Load Zone Change: Change load zone area of the cup while lowering bogie

side frame.

d) Adapter:

i. Crown Surface: Replace if worn to relief depth.

ii. Side Lug: Replace/reverse and use.

iii. Thrust Shoulder: Replace if depth exceeds 0.7mm.

iv. Machined Relief: Replace if depth exceeds 0.8mm.

Summary ROH of Air Brake Wagon with CASNUB Bogie

Box 'N' wagons are to be given Routine Over-Haul (ROH) normally after every 18

months at the nominated sick line/wagon depot, where proper facilities are

provided.

The ROH schedule is as follows:

a) Lift the body, keep it on trestles and run out bogies.

b) Strip bogie components for examinations and repair as below:-

Strip spring and spring suspension arrangement including snubbing

device. Check springs for free height and other defects. Replace

where required.

Examine Bogie frame. Check frame alignment as per RDSO

instructions.

Examine pivot for welding defects/cracks/abnormal depth due to

wear. Replace where necessary and lubricate with graphite flakes to

IS: 495 in dry condition.

c) Strip brake gears levers and rods for examinations of worn outs/damaged

parts.

d) The equipments shall be given attention in accordance with the maintenance

manual issued by respective air brake equipment manufacturers:

i. Cleaning of strainer discs.

ii. Lubrication of brake cylinders/cleaning of its strainer.

iii. Check for easy operation of isolating cocks and anti pilferage device of

distributor valve cut off angle cock, manual quick release and isolating cock.

iv. Draining of auxiliary reservoir.

v. Checking of hose coupling for serviceability.

vi. Cleaning of a strainer.

vii. Dirt collector to be cleaned.

viii. Leakage in pipe and joints to be checked.

ix. After carrying out above items of work the wagon shall be tested for proper

function of air brake system with single car test device in accordance with

the procedure indicated below:

Connect the BP coupling of single car test rig to the corresponding

coupling of the wagon to be tested. The couplings of the other end of

the wagon to be closed with dummy couplings heads. Fix pressure

gauge on the brake cylinder.

The single car test device should now be coupled to the main line of a

compressor through a pipe.

Carry out the preparation and testing in accordance with the

procedure given in the manufacturer's maintenance manual and

record the reading in the Test Performa.

For passing the wagon, all the parameters shall be within specified limits.

e) Clean horizontal levers, Hand brakes and gears and lubricate.

f) Examine head stock for damage, bend/cracks.

g) Refit brake gears, levers and rods. Lubricate pins and other equipments and

apply graphite to horizontal levers of empty load box.

h) Replace worn out brake blocks. Check wheel profile, turn the wheel as

needed. UST of axle to be carried out and turning of wheel to worn wheel

profile during ROH.

i) All the wheels are to be checked ultrasonically and axle box cap bolts are to

be tightened up by torque wrench with proper torque and in no case old

locking plates are to be reused.

j) CBC knuckles are to be checked by contour gauge, anti creep/articulated

rotary operation of locking arrangement to be checked.

k) Manual adjustment of brake gear to be done in accordance with wheel

diameter.

l) Modification works are to be attended as issued by RDSO from time to

time.

Bogie Mounted Brake System

I. In order to overcome the problem faced in conventional bogie breakage,

missing components and malfunctioning of SAB. In BMBS fitted wagons, BK.

Cylinder equipped with in built SAB.

II. In conventional BOXN/BCN wagons due to frequent theft of control rod,

main pull rod.

III. End pull rod & BK. Rigging parts in tippling operation causing poor brake

power in Racks, resulting detentions of wagons. In BMBS wagons these

items are eliminated.

IV. In order to improve mechanical efficiency of brake power.

V. In a normal rake of BOXN wagon fitted with conventional type BK system

there was around 18% brake fading after around a trail of 1000 km. But in

case of BMBS fitted rakes.

No brake fading is observed after around 5000 km.

VI. Braking distance of conventional Rake of 58+1 wagons of BOXN is 1350 m.

However BMBS it is 880 m (approx.).

VII. In conventional wagons setting of a dimension was a major problem. If any

change made in sleeve nuts of E/L device that may create to heavy loss of

wagon creating brakes binding /wheel skidding .In order to overcome this

BMBS fitted wagons came into field which contains in built slack adjuster.

VIII. In case of BMBS system Automatic Load sensing device is used which gives

2.2 kg/cm².

IX. Pressure to brake during empty condition 3.8 kg/cm² during loaded for

avoiding the above problems.

Salient Feature of Bogie Mounted Brake System Used on CASNUB Bogie

Use of two no’s of dia. brake cylinders with automatic load sensing

device.

Use of 58 mm thick K type non asbestos composite brake block.

A constant 56 mm piston stroke is required to maintain uniform and

efficient braking performance.

Application of loads is at the ends the brake instead of Centre

resulted no chances of bending brake beams.

Total slack adjusting capacity 500 mm including brake block wear

wheel wear and all clearances.

All cylinders are equipment with an automatic piston stroke indicator.

Replacement of the brake read quickly and easy removal by only one

pin.

Provision of mechanical hand brake system with the use of two no’s

stainless hand brake cables pulled through standard hand brake

rigging.

Cylinder is mounted parallel to the brake beam and forces through

the bell cranks.

Improves the efficiency and alignments the braking forces with the

wheels which reduced the wear of shoes and wheels.

Use of pressure regulated load sensing device installed between body

and bogie under frame act on 15 psi to maintain normal sensor arm

travel of 95 mm.

WORKING PRINCIPLE OF BMBS:

During application the air is introduced into the brake cylinder which forces out

the piston along the ram assembly. The brake cylinder is floating in nature; as a

result the brake cylinder extends equally on both the sides .The extension of

brake cylinder causes the rotation of the bell crank levers in their pivot, which is

on primary brake beams and forces the push rod to move towards the wheel and

apply force on the wheels. Simultaneously a reduction force is developed which

Cause the primary beams along with levers and brake cylinder to move towards

the wheel. The primary brake beam continues to move until it touches the wheel

and apply force on the wheels. When the brake is released the air from the brake

cylinder is exhausted to the atmosphere through the distributor valve. The return

spring inside the brake cylinder pushes the piston along with the ram assembly

back to its original position .The bell crank levers rotate back causing the beams

to move back to their earlier positions. The brake cylinder is equipped with a

double acting slack adjuster. If there is any wear in brake shoe/wheel or any

slackness in the structure it will be automatically compensated by the built in

slunk adjuster which pays out & fill the gap.

DM YARD

The DM yard is the department where mostly the wagons which have to be

repaired are sent. The wagons sent there are repainted, welded and new

components in place of the damaged ones are provided, new rivets are inserted

and also oxy acetylene cutting takes place etc. The riveting done is hot riveting

and the tail of the rivet is closed using a pneumatic riveter which uses

compressed air and seals the rivet by a continuous series of blows to the end of

the rivet. The temperature of hot riveting is approximately 1000 degrees and the

mild steel rivets used usually catch fire.

PERSONNEL DEPARTMENT

The personnel department is one of the key departments of the company. It performs the following important functions which can be given by as follows:-

1. It arranges work force for the different sections of the company,

2. It also monitors the attendance of staff and the work force.

3. Monitors HRD activities laws of PF/ESI/Gratuity etc.

4. It also looks after personnel welfare.

5. To handle all disputes related on the personnel front.

6. To prepare salary details and advice accounts department to disburse the

salaries.

7. It also invites training applications from students of different colleges and helps

in training them.

8. It also helps in raising funds for personnel welfare.

9. It also helps in the smooth collaboration of the different sections of the

company.

TESTING FACILITIESThe facilities available at the various workshop of Burn Standard is detailed below

 Properties    Description

 Chemical Property tests   Equipment for chemical analysis of ferrous and non ferrous metals such as manganese, phosphorus, sulphur, silicon, nickel, chromium, tungsten, molybdenum and vanadium.

 Physical Property tests   50 ton universal testing machine, notched bar impact testing machine and hardness testing machines.

 Metallography   Zeiss neophot metallographic microscope with accessories for precision polishing and mounting. Equipment for photomicrograph.

Sand testing   A complete range of equipment for the testing of moulding and core sand.

Non-destructive testing   Tensile TestCompression TestImpact TestHardness TestUltrasonic TestMagnetic Crack Detection TestAAR Coupler TestProof Load TestSand Coupling TestUltrasonic Digital Thickness Test by GaugesUltrasonic Flaw DetectorX-ray Machine with Radium survey Meter.

COMMERCIAL DEPARTMENT

This department is responsible for earning revenues for the company. A very

important resource on which the health of the company depends. The functions

performed by the commercial department can be given by as follows:-

1.) This department keeps track of the customer, market intelligence and

competitor’s activities.

2).They also apply their intelligence to ascertain the rates considering

manufacturing costs, overheads, selling expenses visa the acceptance rate to the

buyer under the given market conditions and ensures the company retains a good

profit margin.

3).Wagons is sold to Indian Railways mostly through Rail Board’s open tenders.

However there are private buyers of wagons, who also procure through

tendering/direct contact.

ACCOUNTS DEPARTMENT

Again one of the key department s of the company, the accounts department engages itself in the following activities which have been enlisted here as follows:-

1).This department monitors expenses files returns to the statutory tax departments and makes their due payments.

2).Tracks incomes of finished, semi finished and scrap goods etc and the records are kept in appropriate account books.

3).Tracks all expenses including payments to vendors, employees, contractor, personnel, and statutory payments etc. are kept by them in appropriate books of accounts.

At a specific interval the work out a balance sheet and issue a profit and loss statement every year to ascertain the financial status of the company for the fiscal year.

4).This department also keeps track and makes record of unsold finished goods and unutilized raw goods and its monetary values, receivable money, etc and turns them as assets

5). Money payable to suppliers, staff, statutory accounts, power bill on any account is also kept in the records which they term as liabilities.

CONCLUSION

Burn Standard Company Limited (BSCL) is a Public Sector Undertaking (PSU) of

the Government of India. Headquartered in Kolkata, India, BSCL is engaged

mainly in railway wagon manufacturing under the Ministry of Railways. The

company was formed with the merger of two companies – Burn & Company

(founded 1781) and Indian Standard Wagon (founded 1918),[1] and was

nationalized in 1975. In fiscal 2006, the company reported aggregated

revenues of ₹1373 million (US$21 million). Subsequently the company with its

two engineering units at Howrah and Burnpur came under the administrative

control of Ministry of Railways in September 2010. The refractory unit at

Salem, Tamil Nadu, was transferred to Steel Authority of India Limited.

Several thousand wagons covering all major design have been manufactured and

supplied to Indian Railways and other Industrial Customers. The company is

exploring to enter into the business of coach repair work. The company had

formed a 50:50 joint venture with SAIL, SAIL-BENGAL ALLOY CASTINGS PVT LTD;

incorporated on 12/02/2013.

FUTURE PLAN OF ACTION:* Focus on improved Industrial Relations.* Hiring of Technical experts as advisors/consultants.* Careful investment of CAPEX.* Revival of Steel foundry.* System improvements in out-sourcing.* Reduced cash conversion cycle to improve working capital.* Increased production lines for wagons.* Cost cutting measures.* Enforcement of discipline (Gate attendance, Absenteeism, Productivity)* Re deployment of staff* Induction of retired Railway experts for wagon production* Repair, recondition and augment physical infrastructure for all weather

working, and to remove bottleneck.* Improvement in Basic support services like electricity, water, compressed air to cater to the enhanced production.* Reconditioning of 4T electric arc furnace, 5T electric arc furnace, 6000 lbs jolting machine.* Modification of 10T, 30 T oil fired heat treatment furnace.

OBJECTIVES

To achieve more than 20% growth in turnover in 2014-15. Doubling Steel Foundry molten metal production from maximum of

600T per month to 1200T per month in 2014-15. To implement cost reduction in raw material, reduce electricity and

fuel consumption by 6%. To give thrust to develop non-Railway business. To give thrust on marketing and explore export business. Re-engineering the organization to turn it into a profit making

company and resulting positive net worth in 4-5 years.

After fed in keen interest of the most successful govt. company of west Bengal as

well as India, the BURN STANDARD COMPANY LIMITED from the group of

companies of BHARAT BHARI UDYOG NIGAM LIMITED, I have learnt so many

things from each and every department of this company and with the full

cooperation of all the engineers, officers in charge and workers that as a student

of MECHANICAL ENGINEERING, the technical journey will always be a part of my

life.

The scope and function of the purchase department are to produce and supply of

materials, equipments, machinery and related auxiliary and utility services against

proper documents. Time, quality and price are the main essential factors involved

in purchasing process.

Process:-

Shop department send their demands in a format S-List of loading format

for their requirement.

Purchase department receive number of pieces needed.

Purchase Department issues the enquiry.

Tender called to the registered vendor.

Tender is divided according to the lowest possible price in more than one

bidding.

TENDER RULE

Press Tender (2-2.5 years)

Limited Tender (21 days)

Space Tender