Jessop Coach Woeks Vt Project Smit 2010

7/28/2019 Jessop Coach Woeks Vt Project Smit 2010

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Contents

About the company 1

The Coach Work Division 3

The Bays 4

Flow of resources and products 8

The machines 9

The DGP 20


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About the Company

HistoryThe roots of Jessop & Company Ltd. go back to 1788 when Breen & Company was founded inCalcutta. In 1820, Henry and George, sons of William Jessop acquired Breen & Company on behalf of Butterfly Company established in Derbyshire, England in 1790 by William Jessop. These twocompanies merged together to become Jessop & Company. Subsequently in 1973, the company wastaken over by the Government and Jessop became a Govt. of India undertaking. In 1986, with theformation of Bharat Bhari Udyog Nigam Limited (BBUNL), a Public Sector Holding Company underadministrative control of Deptt. of Heavy Industry, Ministry of Industry, Govt. of India, Jessopbecame a subsidiary of the Holding Company.

During the last two centuries, the company has consistently modernized and streamlined itsproduction facilities to keep abreast with the latest technology and has introduced many newproducts for core sector industries in the country.

Jessop & Co. Ltd.

Founded in 1788 by the sons of William Jessop, an eminent British Engineer.

Now into 3rd Century Operation.

Taken over by Government in 1973.

Disinvested in 2003 through Strategic sale to the Ruia Group.


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Manufacturing Infrastructure at Dum Dum (Near Kolkata Airport),West Bengal

Work Centre Total Area

(sq.mt)

Covered Area

(sq.mt)

Catering to:

1.Structural

& Mechanical

1,11,100 70,500 Cranes,Wagons andStructures.

2.Coach 48,200 29,000 EMUCoaches.

3.RoadRoller,

Mining,

Hydraulics.

84,200 47,400 RoadConstruction, Mining andHydraulicEquipment.

TOTAL 2,43,500 1,46,900


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THE COACH WORK SHOP DIVISIONThe coach workshop division of Jessop & Co. Ltd is one of the five major parts of the

manufacturing infrastructure present at Dum Dum, West Bengal. The major products of this division

are EMU coaches and various other type of railway wagons employed by the Indian Railways all overthe country. Other than being an important part of the Indian Railways, the division also hasinternational presence with coaches plying for the Vietnam Railways

The division has been an important suppliers for the Indian Railways for almost half-a-century now. Since 1962, the the plant has been making EMU coaches according to the company svery own designs. In the recent years , the Indian railway have standardized the system ( due to thearrival of a host of new suppliers from the private and public sectors ) and now only those designsare approved by the integrated Coach factory, Perabur , are followed at this facility.

What goes in . . .The things that enter this facility as raw materials are the virgin sheets and plates of alloys

like mild steel (MS) and the stainless steel (SS) approved by I.R.S. and A.I.S.I. other than these,supporting equipment like bogies (from the adjoining bogie works ), electrical and pneumaticaccessories (from BHEL and other associated suppliers), and internal furnishing equipments (seats,wall /Roof insulation materials, floor sheets, etc) are acquired from outside.

What comes out . . .

The output of the factory are EMU coaches and quality control bodies R.I.T.I.E.S. and R.D.S.O.Currently the workshop is producing BVZI type Guard Coach cum Braking Van and EMU rakesconsists of three units; each of the three units coach consists of three coaches

1 Motor/drivin g car (B- type car; the driving system is fitted to this coach) 1 Trailer car (C -type; the passenger coach) 1 Vendor car (D -type car; 50% vendor + 50% passenger coach)

When put in the service the arrangement of the car is usually as : B-C-D-C-B-C-D-C-B (usually atraincontains two driver cars at two ends with a motor car in the middle; the passenger setting area of D Cars is reserved for female passenger). Prior to dispatch, every coach/wagon is tested for quality atthe testing ring present at the workshop; the MU unit are performance tested under the 25kVoverhead AC supply, available at the facilities.

And what goes in between . . .

The transformer of basic building materials like sheet and plates into rudimentary buildingblocks (likes bracket, beams, ribs, etc) and the assembling of those blocks to the erection of an entiretrain is done in the four bays of this workshop.

In the next few pages, these bays have been described briefly followed by the description of the various machine and other important supporting units present in the plant.


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BAY-1: BODY SHELL ASSEMBLYSalient Features

The Bay-1 is the first bay of the four bays present in this plant. This is where the body shell of acoach is assembled. the primary operations done here is the assembling of various componentsmanufactured at the preparation bay, by various types of welding processes.

Legend

The inputs to the bay are:

* Underframe (from Bay-3)

* Strutural members (from Bay2&3)

* Strategically bent panels (fromBay-2)

The output from this bay is the bare body-shell of coaches ready for the furnishing operations of Bay-4


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BAY-2: PreparationSalient Feature

Legend

The Bay-2 is the second bay and the heartof this workshop. This bay supplies to allthe other three bays with variouscomponents needed in the coach assemblywork. The primary operations done hereare shearing, bending, pressing, rolling,cropping, profiling, drilling, etc, of sheetsand plates to form components which canbe assembled in the other bays.

The inputs ot this bay are standard MS andSS sheets and plates.

The outputs from this bay are thenumerous components that are necessaryin the other bays. Some of thosecomponents are:

* Beams of various sections (C-section, Z-section, L-sections, etc.) bent by pressesare used in the underframe assembly.

* Sheets rolled by the rolling mills are used as panels in the bodyshells.

* Special profiles made from sheets and plates are used as structural components in building theskeletal structure of the coach.


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BAY-3: UNDERFRAME & PREPARATIONSalient Feature

Legend

The third bay, Bay-3, is divided intotwo parts-underframe assembly andpreparation. In the first segment, theunderframe of the various coachesand wagons are prepared from thecomponents supplied from thepreparation bays (Bay-2 and half of Bay-3). The primary operations of thisbay are welding (by techniques likeMIG, MAW, electric arc, etc), fettlingand grinding (using primarilypneumatic grinders). The secondsegment belongs to preparationsection which has already beendiscussed.

The inputs to this bay are thestructural components manufacturedin the preparation bays.

The output from this bay is the finished underframe of bogies and coaches which will be dispatchedto Bay-1 where the body-shell will be constructed on the underframe.


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BAY 4: SUB-ASSEBLY / FURNISHINGSalient Features

Legend

The Bay-4 is the last bay of the workshop. This is whereall the furnishings, fittings(both pneumatic andelectrical) and painting jobs

are done, The mainoperations done here is thefurnishing, where theinternal fittings of the EMUcoach (seating, separator,electrical wirings and

fittings) are done. Here the walls, roof and floor or the coach are prepared (wall & roof insulations,separators and structures)for the coach to be put into service. The electrical and pneumatic fittingsused here are purchased from outside.

The inputs to this bay are:

* The bare body-shell (assembly of all the walls, roof and underframe prepared in bays 1 and 3).

* The electrical and pneumatic accessories purchased from outside.

* Paints and all paint related accessories (like putty, red-oside, primed etc.)

* Floor sheets, wall, roof insulations (like steel-wool, SS floor sheets, preformed plywood, etc.) andfurnishing items (seats, B-car console room structure and other separators, doors, windows, etc.)

The outcome is a fully functional coach ready to be mounted on bogies and dispatched after testing.


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FLOW OF RESOURCES AND PRODUCTS

The flows of the variors rawmaterials, finished componentsand structural building memberswhave been shown in the abjoiningillustrtion. At first glance, thepositicning of the bays may seembaffling-especially when weconsider the flow of theunderfrme and body-shell. Thegeneral opinion wouke be to place

the body-shell bay after the onewhere the underfrme isassembled so that the heavystructures would not have to behauled back and forth.

This is where the concept of material handling and especially the minimization of it come into play. On careful observation, onecan understand that the peparation bays (Bay-2 and half of Bay-3) have been strategically placed inthe middle of the workshop since it feeds all the four bays. But this also means that a greater

amount of crane-work has to be done to move the body-shell and the underframe. It is actually acompromise vbetween the costs cut by placing the preparation bays in the middle, and extraexpenses in the form ofthe crane-work done in hauling the large structures (body-shell andunereframe) over lone distances.

The material handling devices used in this workshop are mainly hand-pulled trolleys (for light loads),battery driven electric cars (for loads up to 1.5 Tons) and Electric Overhead Travel (EOT) cranes (forvloads in the region of 10-15 tons).


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THE PECO MACHINE

Important Feature

Machine name : Peco (Seam/resistance Welding Machine)

Manufactured By : Elektrische Schwei maschinen

Primary function : Seam welding Resistance Welding.

Input limit : SS and MS sheet of a maximum thickness of 2.5mm.

Machine capacity : Sheets of thickness 2.5 mm (maximum) canbe welded with welds of length of about2.0m (safe range).

Faction of machine (as required at the plant) : Seam/Butt welding of sheets to formwider/longer sheets as per requirements.

Jibe here done : Roof sheet, Side panel, End panel, etc.

Work force requirements : 4(minimum; 1 operator + 3 for materialhandling.

Total number of similar machine present : 1(Bay-2)

Location in the bay (according to illustration) : 35

The machine number : 1474


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NIBBLING MACHINE

Important Feature

Machine name : Nibbling machine (Single Point cutting toolwith vibrator motion).

Manufacture by : WMW.

Primary Fuction : Profile cutting of sheets fed into themachine manually.

Input limit : MS and SS sheets of a maximum thicknessof about 3.15 mm.

Machine capacity : The machine can shear sheets of amaximum thickness of 3.15 mm by a singlepoint cutting tool which executes verticalvibrator motion. The feed and depth of cutcan be varied according to the sheetthickness.

Fuction of the machine : Pre-marked sheet with the requiredProfile marked on them are fed into the

machine manually and thereafter themotion of the sheet (towards the cutter) iscontrolled by hand so as to make line of cutcoincide with the marked line.

Jobs done here : Car-line (roof), Sidr panel, etc.

Work force requirements : 1 for smaller jobs (minimums; operator andfeeder), usually 5 people are needed forlonger jobs (2 to push the sheet + 1 to guide

the sheet +2 to pull the sheet comong out of the machine.

Total number of similar machines present : 2(1 abondoned; both in bay-2)

Location in the bay in the bay : 34(fuctional, Bay 2)

The machine number(s) : 1240, 1241(abandoned)


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CNC profiling machine

Important Features

Machine name : CNC Profiling Machine(CNC Gas Cutting Machine)

Manufactured by : MayurSP, Indian Oxygen Ltd., Mumbai

Primary function : Profile cutting of sheets and plates according to data fed intoits Computer

Input limit : MS and SS plates of a maximum thickness of 25 mm

Machine Capacity : 15000 mm x 3000 mm plates of a maximum thickness 55 mm

Functions of the machine : Gas cutting of plates to create intricate and accurate profile(as required at the plant) for maximum utilization of the available materials(plates)

Jobs done here : Side frame (bogie), Bolster (under frame), Bolster web etc

Workforce requirements : 2 (minimum; 1 operator + 1 for job setting and supervision)

Total number of similar : 1 (Bay-2)machine present

Location in the bay : 37(according to theIllustration)

The machine number(s) : 1875


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Notching & punching machineImportant Features

Machine name : Combine Shearing and Punching Machine with Notcher

Manufactured by : Peddinghaus

Primary function : Cropping, bar cutting, plate shearing, punching, angle cuts(90 ,45 )

Input limit : MS and SS sheets and plates of a maximum thickness of about 12 mm

Machine Capacity : Sheets and plates of a maximum thickness of about 12 mm)

Functions of the machine : Creating notches and slots in components (usually(as required at the plant) pre-machined) to facilitate further processes (like bending,

Slots to provide passage for electrical/pneumaticConnections)

Jobs done here : Ribs (under frame), brackets etc.

Workforce requirements : 1 (minimum; operator and job setter come materialhandler, 4 work simultaneously and independently on themachine).


Location in the bay : 30, 35, 37 (Bay-3)(according to theillustration)

The machine number(s) : 1239, 1014, 1428


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The Ungerer Rolling Machine

Important Features

Machine name : Precision Sheet Rolling Machine

Manufactured by : Ungerer, Pforzheim, Germany

Primary function : Sheet rolling (at any angle) and straightening

Input limit : MS and SS sheets of a maximum thickness of about3.15 mm

Machine Capacity : Sheets 3200 mm wide and of thickness of 3.15 mm(maximum) can be safely rolled in the machine (roller lengthis about 4000 mm)

Functions of the machine : Rolling and straightening of sheets as required in the body(as required at the plant) shell manufacturing (Bay-1)

Jobs done here : Roof sheet, ceiling-bend etc

Workforce requirements : 2 (minimum; 1 operator + 1 for job setting, material handlingand general supervision)


Location in the bay : 32 (Bay-2)(according to theillustration)

The machine number(s) : 1495 (Bay-2)


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Heavy pressing machineImportant Features

Machine name : Hydraulic pressing Machine

Manufactured by : Hindustan Machine Tools

Primary function : Pressing of sheets, plates and blanks using heavy duty dies

Input limit : The maximum thickness of the input plates varies accordingto the dies used

Machine Capacity : Pressing force of 1000 Tons (Bay-2), 600 Tons (Bay-4)

Functions of the machine : Usually blanks (MS and SS sheets) are pressed in this machine(as required at the plant) give them a desired shape (e.g. window forms)

Jobs done here : Window forms, Tan trail, Floor sheets etc.

Workforce requirements : 1 operator + material handling and job setting (varies with job sizes)

Total number of similar : 2 (1 in Bay-2 + 1 in Bay-4)machine present

Location in the bay : 2 (Bay-2)(according to the 19 (Bay-4)illustration)

The machine number(s) : 1751 (1000 Tons, Bay-2)2007 (600 Tons, Bay-4)


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Drilling machine Important Features

Machine name : Radial Drilling Machine

Manufactured by : Kitchen & Wade Ltd., Halifax, England

Primary function : Drilling holes of various sizes on the components usingVarious standard drills

Input limit : Plates of a maximum thickness of about 70 mm can be safelydrilled using a suitable drill. A pilot drill is necessary whenmachining holes of diameter in excess of 25 mm

Machine Capacity : The arm length of the machine is about 1.2 m (usually it variesbetween 1m and 1.5 m). So the drilling head can bepositioned anywhere within a radius of about 1.1 m aboutthe base. The vertical travel of the drilling head can be of about 500 mm. By using suitable drilling techniques, stackedup plates with a combined thickness of ~120 mm can besafely machined

Functions of the machine : Almost all the drilling work necessary to the production(as required at the plant) process followed in the plant is performed by these machines

using standard drills. The non-standard sizes and holes of large diameters are usually machined on the vertical boringmachine available

Jobs done here : All types of drilling holes

Workforce requirements : 1 (minimum; operator, job setter and handling)

Total number of similar : 26 (16 in Bay-2 + 10 in Bay-3)machine present

Location in the bay : 11, 13, 14, 16, 17, 18, 19, 20, 23, 24, 25, 26, 27, 28, 29, 30(according to the (Bay-2)illustration) 22, 23, 24, 25, 26, 27, 28, 29, 32, 33 (Bay-3)

The machine number(s) : 1366, 1026, 1022, 1361, 1030, 1631, 1691, 1031, 1034, 1072,

1038, 1037, 1364, 1024, 1342(Bay-2)

1019, 1367, 1023, 1020, 1032, 1667, 1021, 1756, 1033, 1017

(Bay-3)


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SINGLE COLUMN PRESSING MACHINE

Important Features

Machine name : Single Column Hydraulic Pressing Machine

Manufactured by : Sachs & Grimm

Primary function : Bending of sheets and plates by use of variousdies.

Input limit : MS and SS sheets and plates of a maximumthickness of about 12 mm.

Machine Specification : Pressure = 40,000 kgStroke of arm = 500 mmThroat height = 800 mmThroat depth = 325 mm

Function of the machine(as required at the plant) : All type of light bending work (of small handheld components) on pre- marked cut peicesare usually done on these machines.

Jobs done here : Usually small angle bends, brackets, etc.

Workforce requirements : 1(minimum; operator and handling)

Total number of similar machines present : 5 (Bay-2)

Location in the bay(according to the illustration) : 22, 40, 42, 43, 44 (Bay-2).

The machine number(s) : 1343, 1344, 1252, 1342, 1347 (Bay-2).


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ROLLING MACHINE Important Features

Machine name : Plate Bending Machine

Manufactured by : Bajaj Machinery Corporation

Primary function : Rolling and straightening of sheets and platesas per the requirementsof the workshop.

Input limit : MS and SS sheets and plates of a maximumthickness of about 4 mm can be bent in thismachine.

Machine Specification : Diameter of all three rollers = 180 mmMaximum width rolled = 4000 mmMinimum diameter formed = 300 mmMaximum diameter formed = Unlimited

Rolling motor = 10 HPPinching motor = 5 HPBottom roll adjustment = ManualSwing arm opening motor = ManualMaximum admit dimensions = 4 mm* 4000 mm

Function of the machine (as required at the plant) : Straightening out undulations of sheets andplates and also rolling of sheets as perrequirements of the workshop.

Jobs done here : Sidepanel bends, Roof Sheet bends, etc

Workforce requirements : 1+ (1 operator + handling, setting andsupervision as demanded by the job)

Total number of similar machines present : 2 (Bay-2)

Location in the bay(according to the illustration) : 7, 8 (Bay-2).

The machine number(s) : 1013, D-1029 (Bay-2).


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THE DGPThe dgp or Degreasing Granodising Plant is a very important post processing plant of the

EMU Coach Works Division. The main operation done here is the phosphating process. This gives thecomponent (Sheets, plates and finishing components) the necessary protection (a Zinc chromateprotective layer) which is needed to survive the service conditions. The components are usually thestarting materials like sheets and plates, if the finished component is too large for the availabletanks. In all other process (as this also provides protection for the welds and other joints).

There are seven tanks in the plant, all having approximate inner dimensions91016604560mm. The 1 st tank is for degreasing treatment, 2 nd tank is for rinsing the degreasingmaterial, 3 rd tank is for derusting operation, 4th tank for rinsing the derusting material, and 5th tankfor phosphating treatment, 6 th is for rinsing of phosphate material and 7 th tank for passivationoperation.

Degreasing Rinsing Derusting Rinsing Phosphating Rinsing Passivation

(5-15 mins.) (3 mins.) (10-30 mins.) (5 mins.) (2-5 mins) (2 mins.) (5 mins)

85 C- 90 C 65 C -75 C 65 C -70 C ~25 C

The DGP plant at the EMU Coach Works Division has undergone some recentmodification some recent modifications by incorporating some new chemicals in place of thetraditional ones 14 th June, 2007.

Old Chemical New ChemicalNew Mixture Ratio(water + chemical)

FERRPCLEAN-S101 FERRPCLEAN-K-20 (5000lit + 200kg)PHOSCLEAN- 170 PHOSCLEAN-125 (4000lit + 1000lit)P.T. PHOS-20 P.T. PHOS-199 (5000lit + 200lit)PASSILYTE-10 PASSILYTE-107 (5000lit + 1.5lit)


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DEGREASING TANKImportant Data

Name of reagent : FRERROCLEAN-S101

Nature (Acidic/Alkaline) : Alkaline

pH : >11

Points : 39 to 80

Time of treatment : 10 to 15 minutes

Temperature : 80c to 90c

Bath composition : 50 to 100 kg for each 1000 liters

Per 1000 liter Pointage

50 kg 39

70 kg 55

90 kg 71

Replenishment : Adding 975 gm reagent per 1000

liters for each point lacking.

Maintenance : Bath may be required to bediscarded partly or fully at an interval of 60 to 90 days

The FERROCLEAN-S101 bath is controlled in the plant by titration according to the followingmethod:

1. Pipette 10 ml cooled sample of FERROCLEAN-S101 bath solution into a 250ml conical flask.

2. Add 2-4 drops of Methyl Orange.

3. Fill the burette to the zero mark with 0.1N Sulphuric Acid.

4. While stirring sample slowly run in o.1N Sulphuric Acid from the burrete until the colour changefrom yellow to red occurs.

5.Record the number of millimeters of 0.1n Sulphuric Acid consumed.


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DERUSTING TANK

Important Data

Name of reagent : PROCLEAN 170

Nature (Acidic/Alkaline) : Acidic

pH :


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PHOSPHATING TANK

Important Data

Name of reagent : P.T.PHOS 20

Nature (Acidic/Alkaline) : Acidic

pH :


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PASSIVATION TANK

Important Data

Name of reagent : PASSILYTE

10Nature (Acidic/Alkaline) : Acidic

pH :

Jessop Coach Woeks Vt Project Smit 2010

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