Revised Training Module For Mechanical Department Supervisor Final Total PDF
Revised Training Module For Mechanical Department Supervisor Final Total PDF
Revised Training Module For Mechanical Department Supervisor Final Total PDF
ffi$'
cs
Government of India (Bharat Sarkar)
Ministry of Railways (Rail Mantralaya)
(Railway Board)
RBE No. v zl2o2o
No. E(MPP)2oL9/3/4a New Delhi, Dated t* o3.2020
3. The revised modules prepared have been scanned and uploaded under
E(MPP) Traininq Circulars and can be viewed or downloaded from railnet.
lt,
r{d*
W_
\d
"€h0
\.-,'
CI r. (ltta e rora Misra)
Principal Executive Directo, Trg. & MPP
way Board.
No. E(M PP)2019/3/48 New Delhi, datedt l?ro3-2o2o
Copy to:
u)1
8) The General secretary, NFIR,3 chelmsford Road, New Delhi for information with
35s pares
( -sfrn e General secretary, AIRF,4 state Entry Road, New Delhi for information with 35
spares.
f \.ia' The Secretary General, FROA, R.No.256-A, Rail Bhavan, New Delhi for
information with 5 spares.
o ) The Secretary General, IRpOF, R.No.268. Rail Bhavan, New Delhi for
information with 5 spares.
92) All Members, Department council & Secretary staff side National Council 13-C,
Ferozeshah Road, New Delhi with 90 spares.
) The Secretary General, AIRPF Association, Room No.256-D, Rail Bhavan, New
Delhi with 5 spares.
74 ) General Secretary, All India SC & ST Railway Employees Association, t7L/B-3,
Basant Lane Railway Colony, New Delhi ( 15 copies).
Copy to:
vii)
0 \V
PS & ED(PG) to MR, MSR(A) & MSR(K)
viii) PSO/ST.PPS to CRB, FC, ML, ME, MM, MS, MT, DG(RHS) & DG(RPF)
ix) ST.PPS/PPS/PS to AM(Budget), AM(CE), AM(CArS), AM(Commt.), AM(Etect),
AM(Fin), AM(Mech.), AM(Plg.), AM(project), AM(pU), AM(Sig.), AM(Stafl,
AM(RS), AM(T&C), AM(Tele), AM(Traffic), AM(Works), Adv.L(RS), Adv(Vis.),
Adv.Fin(Exp), Adv(IR), Adv(Safety), LA, OSD(MIS).
x) ED(Plg.), ED(Accts.), EDF(BC), EDCE(B&S), EDCE(G), EDcE(ptg.), ED(CHG),
ED(CC), ED(C&IS), ED(E&R), EDEE(Dev), EDEE(G), EDE, ED(RRB), EDE(N),
EDE(Res), EDF, EDF€, EDF(S), EDF(B), EDF(RM), EDF(x)r, EDF(x)rr, ED(H),
EDLM, ED(MIS), EDE(cC), ED(T&Mpp), EDME(chg.), EDME(Fr.), EDME(Tr.),
EDME(TOT), EDME(Dev.), EDME(W), ED(pC)r, ED(pC)rr, ED(pp), ED(project),
ED(Project)/DMRC, EDRE, ED(Safety), JS, JS(C), JS€, JS(p), rG./RpF(irqs),
IG/RS, ED(S99.), ED(Stat&Econ.), EDRS(C), EDRS(c), EDRS(p), EDRS(S),
EDRS(w), ED(rD), EDrr(M), EDr(MC), EDr(p), ED(r&c), EDcE(p), ED(pM),
ED(pG), EDrC-r, EDrC(FM), EDrr(F), EDrr(FM), EDrr(s), EDV(A), EDVE,
EDV(r), ED(w).
xi) Chief Commissioner of Railway Safety, Lucknow.
xii) E(rrg.), E(NG)I, E(NG)II, E(G), F(E)I, F(E)II, F(E)rrr, E(scr)r, E(scr)rr branches
of Railway Boa rd.
Scanned by CamScanner
Revised Training Module
for
Mechanical Supervisors
(February 2020)
Index
Abstract of Modules
Page 1 of 118
ABSTRACT OF MODULES
Module Duration in
SL. NO. Name of Post Stream No. Weeks Page No
1 Sr. Section Engineer C&W MSE-C 52 3-4
2 Sr. Section Engineer Diesel MSE-D 52 5-6
3 Sr. Section Engineer Workshop MSE-W 52 7-8
4 Junior Engineer (RRB) C&W MJR-C 52 9 - 10
5 Junior Engineer (RRB) Diesel MJR-D 52 11 - 12
6 Junior Engineer (RRB) Workshop MJR-W 52 13 - 14
7 Junior Engineer C&W MJI-C 52 15 - 16
8 (Intermediate)
Junior Engineer Diesel MJI-D 52 17 - 18
9 Junior Engineer
(Intermediate) Workshop MJ1-W 52 19 - 20
10 (Intermediate)
Junior Engineer C&W MJP-C 13 21
11 Junior Engineer
(Promotional) Diesel MJP-D 13 22
12 Junior Engineer
(Promotional) Workshop MJP-W 13 23
(Promotional)
Module Code
1. M Mechanical
2. SE Section Engineer
3. JR JE- RRB
4. JI JE- Intermediate
5. JP JE-Promotional
6. C C&W
7. D Diesel
8. W Workshop
Subject Code
1. M Module
2. R Railway
3. E Engineering
4. T Theory
5. C C&W
6. D Diesel
7. W Workshop
Page 2 of 118
MODULE - MSE C
Page 3 of 118
Duration Activity
Session Type Subjects Subject
in weeks Centre
Stream specific theory MCT-02 08 STC
Accident & Disaster
MRT-08 01 IRIDM
THEO management
III Train operations with
MRT-11 02 ZRTI
signaling
Stores 01 Parent Unit
Field
PRACT Drawing Office and Respective
Visit 01
HQ Control office Unit/Units
Page 4 of 118
MODULE - MSE D
Name of the
Sr. Section Engineer
Post/Category
Stream Diesel
Mode of appointment Through RRB
Min. Qualification Degree in Engg. (Mech / Elect /Electronics)
Total Duration of Training
52 Weeks
Period
Page 5 of 118
Duration Activity
Session Type Subjects Subject
in weeks Centre
Tender & Contract MRT-07 01 STC
THEO Managerial Skills MRT-09 02 STC
Stream specific theory MDT-01 04 STC
C&W Depot 01
II CMT Lab 01
Field Diesel Loco POH Respective
PRACT
Visit Shop & Electric 03 Places
Loco POH Shop
DEMU Shed 01
MDT-02
Stream specific theory 08 STC
M/E
Accident & Disaster
THEO MRT-08 01 IRIDM
management
III Train operations with
MRT-11 02 ZRTI
signaling
Stores 01 Parent Unit
Field
Drawing Office and Respective
Visit 01
HQ Control office Unit/Units
Page 6 of 118
MODULE - MSE W
Name of the
Sr. Section Engineer
Post/Category
Stream Workshop
Mode of appointment Through RRB
Min. Qualification Degree in Engg. (Mech / Elect /Electronics)
Total Duration of Training
52 Weeks
Period
Page 7 of 118
Duration Activity
Session Type Subjects Subject
in weeks Centre
Page 8 of 118
MODULE - MJR C
Name of the
Junior Engineer
Post/Category
Stream C&W
Mode of appointment Through RRB
Min. Qualification Diploma in Engg. (Mech / Elect /Electronics)
Total Duration of Training
52 Weeks
Period
Page 9 of 118
Duration in Activity
Session Type Subjects Subject
weeks Centre
Stream specific theory MCT-02 08 STC
Accident & Disaster
MRT-08 01 IRIDM
THEO management
III Train operations with
MRT-11 02 ZRTI
signaling
Stores 01 Parent Unit
Field
PRACT Drawing Office and Respective
Visit 01
HQ Control office Unit/Units
Page 10 of 118
MODULE - MJR D
Page 11 of 118
Duration Activity
Session Type Subjects Subject
in weeks Centre
MDT- 02
Stream specific theory 08 STC/ DTTC
M/E
Accident & Disaster
THEO MRT-08 01 IRIDM
management
III Train operations with
MRT- 11 02 ZRTI
signaling
Stores 01 Parent Unit
Field
Drawing Office and Respective
PRACT Visit 01
HQ Control office Unit/Units
Page 12 of 118
MODULE - MJR W
Name of the
Junior Engineer
Post/Category
Stream Workshop
Mode of appointment Through RRB
Min. Qualification Diploma in Engg. (Mech / Elect /Electronics)
Total Duration of Training
52 Weeks
Period
Subject Duration
Session Type Subjects Activity Centre
code in weeks
Railway Organization &
MRT-01 03
Management
Role of Mechanical Dept. MRT-02 01
Rolling Stock Theory- Carriage MRT-03
Rolling Stock Theory - Wagon MRT-04
THEO STC
Rolling Stock Theory - Diesel 03
Loco, DEMU, SPART, Train Sets: MRT-05
MEMU/ EMU
I
Industrial Safety, First aid &
MRT-06 01
Firefighting
Coach Production Unit 02 ICF/RCF/MCF
Any wagon
Field Wagon Production Unit 01 prod, unit /
PRACT
Visit workshop
RWF 01 RWF
RDSO 01 RDSO
Page 13 of 118
Duration
Session Type Subjects Subject Activity Centre
in weeks
Stream specific theory MWT-02 05 STC
Stream specific theory MWT-04 02 BTC
THEO Accident & Disaster MRT-08 01 IRIDM
management
III Train operations with signaling MRT-11 02 ZRTI
Stores 01
Parent Unit
Field CMT Lab 01
PRACT
Visit Drawing Office and Respective
01
HQ Control office Unit/Units
Page 14 of 118
MODULE - MJI C
Page 15 of 118
Duration Activity
Session Type Subjects Subject
in weeks Centre
Industrial Safety, First aid &
MRT-06 01
Firefighting
STC
Tender & Contract MRT-07 01
THEO
Managerial Skills MRT-09 02
Computer Awareness MRT-14 01
III Technical English MRT-15 01 STC
Stream specific theory MCT-01 04
C&W
C&W Workshop 01
Workshop
Field Divisional control Respective
PRACT 01
Visit office Unit
ICF/RCF/
PU Training 01
MCF
Page 16 of 118
MODULE - MJI D
Page 17 of 118
Duration Activity
Session Type Subjects Subject
in weeks Centre
Industrial Safety, First aid &
MRT-06 01
Firefighting STC
Tender & Contract MRT-07 01
THEO Managerial Skills MRT-09 02
Computer Awareness MRT-14 01
III Technical English MRT-15 01 STC
Stream specific theory MDT-01 04
Diesel POH
01
Workshop Respective
Divisional control Unit
Field 01
PRACT office
Visit
DLW/DMW/
Diesel Loco PU
01 DLF (MEW)
Training
& RDSO
MDT-03
Stream specific theory 04 STC/DTTC
M/E
THEO
MDT-04
Stream specific theory 04 STC/DTTC
M/E
IV Diesel Shed 01
Practical Training in Welding
PRACT 01 Parent Unit
specific
On Job Training 02
Refreshing /Examination/Viva 01 STC
TOTAL 52
Page 18 of 118
MODULE - MJI W
Page 19 of 118
Duration Activity
Session Type Subjects Subject
in weeks Centre
Industrial Safety, First aid &
MRT-06 01
Firefighting STC
Tender & Contract MRT-07 01
III THEO Managerial Skills MRT-09 02
Computer Awareness MRT-14 01
Technical English MRT-15 01 STC
Stream specific theory MWT-03 06
Field ICF/RCF/MC
PRACT PU Training 01
Visit F
Page 20 of 118
MODULE - MJP C
Page 21 of 118
MODULE - MJP D
Page 22 of 118
MODULE - MJP W
Page 23 of 118
Annexure - II
Page 24 of 118
Index of subjects common to all streams
Sl. Subject
Name of Subject Module Page No.
No. Code
Railway Organization &
1 MRT - 01 MSE, MJR & MJI 26
Management
2 Role of Mechanical Department MRT - 02 MSE, MJR & MJI 27
MRT -
3 Rolling Stock Theory – C/D/W MSE & MJR 28
03,04,05
Industrial Safety, First Aid & Fire
4 MRT - 06 MSE, MJR & MJI 29
Fighting
Tenders & Contract
5 MRT - 07 MSE, MJR & MJI 30
Management
Accident & Disaster
6 MRT - 08 MSE, MJR & MJI 31
Management
7 Managerial Skills MRT - 09 MSE, MJR & MJI 32
Welding and Non-Destructive
8 MRT - 10 MJR & MJI-W 33
Testing
MSE, MJR & MJI-
9 Train Operations with Signaling MRT - 11 34
C&D
10 Integrated Course at IRIMEE MRT - 12 MSE, MJR 35
11 Introduction to Rolling Stock MRT - 13 MJI 36
12 Computer Awareness MRT - 14 MJI & MJP 37
13 Technical English MRT - 15 MJI 38
Industrial Safety, First Aid & Fire
14 MRT - 16 MJP 39
Fighting
Accident & Disaster
15 MRT - 17 MJP 40
Management
16 Supervisory Skills MRT - 18 MJP 41
17 Technical English MRT - 19 MJP 42
18 Applied Mechanics MET - 01 MJI 43
19 Hydraulics MET - 02 MJI 44
20 Manufacturing Process MET - 03 MJI 45
21 Engineering Drawing MET - 04 MJI 46
22 Electrical Engineering MET - 05 MJI 47
23 Strength of Material MET - 06 MJI 48
24 Heat Engine & Thermodynamics MET - 07 MJI 49
25 Theory of Machines MET - 08 MJI 50
26 Material Science MET - 09 MJI 51
27 Machine Design & Drawing MET - 10 MJI 52
28 Industrial Engineering MET - 11 MJI 53
29 Manufacturing Process MET - 12 MJP 54
30 Industrial Engineering MET - 13 MJP 55
31 Engineering Drawing MET - 14 MJP 56
Page 25 of 118
SUBJECT NAME RAILWAY ORGANISATION & MANAGEMENT
SUBJECT CODE MRT - 01
MODULE MSE, MJR & MJI
TIME IN
SL NO. TOPIC
HRS
1 Organization of Indian Railways 03
2 Recruitment and training 03
3 General Conditions of service, APAR 03
4 Medical Attendance Rules 02
5 Leave Rules 03
6 Pass Rules 03
7 Conduct Rules 02
8 DAR 06
9 Payment of Wages Act 02
10 Minimum Wages Act 01
11 Workmen’s Compensation Act 02
12 Hours of Employment Regulations 03
13 Factories Act 02
14 Industrial Disputes Act 03
15 NPS, RESS, PF, Pension & Other Retirement benefits 04
16 Welfare Measures, Privilege for differently abled person 03
17 Organization and objectives of Stores branch 02
18 Classification and Codification of Stores 03
19 RTI, CPGRAMS 03
20 Purchase Agencies: IREPS, Use of DSC, GeM, 03
21 Procurement of stores - Non-Stock 04
22 Recoupment of stores - Stock item 04
23 Drawal of Stores 03
24 Scrap disposal 03
25 Disposal of surplus stores 01
26 Inventory Control, IMMIS 03
27 Organization and objectives of Accounts branch 02
28 Budgeting 03
29 Parliamentary control of Railways 02
30 Classification of Expenditure 03
31 Stock Verification 02
32 Delegation of Powers, MSOP 01
M&P, Rolling stock and Works Programme: IRPSM, IRMNP and
33 06
RSP portals
34 Audit Paras 03
35 Yoga & meditation 06
36 Rajbhasha 03
37 REVIEW 03
Total 108
Page 26 of 118
SUBJECT NAME ROLE OF MECHANICAL DEPARTMENT
SUBJECT CODE MRT-02
MODULE MSE, MJR & MJI
TIME IN
SL NO. TOPIC
HRS
1 Organization and objectives of Mechanical Dept. 03
Types of Rolling stock-
2 02
Production/Repair/Maintenance practices of same
Production units:
3 03
Brief History, Activities
Workshops:
4 Role of C&W Workshop, Objectives, Organization, Layout, 06
Activities of different shops
Workshops:
5 Role of Diesel POH Workshop, Objectives, Organization, Layout, 05
Activities of different shops
C&W Depot:
6 Role of C&W Depot, Objectives, Organization, Layout, Activities of 04
different sections
Diesel Sheds and EMU/MEMU/DEMU Shed:
7 Role of Sheds, Objectives, Organization, Layout, Activities of 06
different sections
Latest Development in Mechanical Dept. /Other Organizations-
8 02
RDSO, IRIMEE, RITES, CONCOR, CAMTECH
EnHM: Role of EnHM, Organization, objectives, funds for EnHM
9 02
works
10 Review 03
Total 36
Page 27 of 118
SUBJECT NAME ROLLING STOCK THEORY
SUBJECT CODE MRT-03, 04 & 05
MODULE MSE, MJR
TIME IN
SL NO. TOPIC
HRS
MRT-03
Types of Coach and their nomenclature, Codal life, Transportation
1 03
Codes, Coach numbering system
2 Introduction of Coach Shell: ICF and LHB Coach 02
3 Wheel set- wheel, axle & bearings 04
Introduction of Different types of Bogie for Rolling Stock and
4 06
Suspension system including Air Suspension
Types of Draw and Buffing Gears in Coaches and Wagons: An
5 06
Introduction
6 Air & EP Brake system; Brake riggings 09
Furnishing items: ICF and LHB, EMU/MEMU coaches, Safety &
7 04
amenity fittings
8 Maintenance practice in coaching stock 03
MRT-04
Types of wagon stock, their nomenclature, Codal life,
9 03
Transportation Codes, Wagon Numbering System
10 Types of bogies in wagon stock 03
11 Features of special wagons/latest wagons 03
12 Pattern of freight train examination 03
Weighbridge, WILD and other way side monitoring systems:
13 03
Overview
MRT-05
Diesel locomotives - types, Introduction of Electric Loco,
14 03
EMU/MEMU & Train-Sets
Important systems in a diesel locomotive: Fuel oil, lube oil, cooling
15 15
water, turbo supercharging & brake system
Electrical control system in Locomotives and Train-
16 06
Sets/EMU/MEMU
Latest development in Rolling Stock including Locomotives &
17 06
Train-Sets
18 DEMU: Power and Trailing cars, important features and systems 05
19 SPART- Introduction, Basic arrangements, importance. 01
20 Visit to model room/coaching/wagon depot/workshop & loco shed 14
21 Review 06
Total 108
Page 28 of 118
SUBJECT NAME INDUSTRIAL SAFETY, FIRST AID & FIRE FIGHTING
SUBJECT CODE MRT-06
MODULE MSE, MJR & MJI
TIME IN
SL NO. TOPIC
HRS
Causes of fire;
1 02
Identification of unsafe conditions and unsafe acts
2 Identifying and handling of various types of fire extinguishers 04
3 Precautions to be taken while extinguishing fire 02
Render first aid to the burn injuries
4 Render first aid to persons affected by suffocation; 02
Communication
5 Scope and Rules of first Aid; Structure and function of body 02
General idea about circulation of blood; Wound & Hemorrhages;
6 02
Dressing & Bandages
7 Shock & its management; Asphyxia & Artificial respiration 02
Injuries to bones & joints - fractures; Unconsciousness and
8 02
General rules for the treatments of unconsciousness person
Practical demonstration of Transport of injured persons, stretcher
9 exercises, preparing and blanketing stretcher, Basic Life Support 03
Training
Principles of Accident, Causation & its Prevention, Unsafe Acts &
10 03
Unsafe Conditions
11 House Keeping, EOT Crane Operation & Material Handling, 5S 02
Safety on Small Tools, Electrical Appliances, Welding & cutting
12 02
gases, Working on heights
13 Use of PPE, Mock Drills 03
Role of Supervisors on Safety, Accident Reporting &
14 02
Investigations
15 Review 03
Total 36
Page 29 of 118
SUBJECT NAME TENDERS & CONTRACT MANAGEMENT
SUBJECT CODE MRT-07
MODULE MSE, MJR & MJI
TIME IN
SL NO. TOPIC
HRS
Introduction on Estimate preparation to sanctioning and from
1 02
Detailed Estimate to entering into contract agreement
2 Overview of contract management 02
Types of contracts, revenue contracts / work contracts, schedule
3 03
of powers for approval of works, works programme
4 Service Contracts, GCC for services, SBD 03
5 Initiation of tenders, Types of tenders, Selection of tenders
03
Sanction to float tender & Tender notice
Preparation of tender documents, Elements of tender document,
6 General conditions of contract, Special conditions of contract, 03
Tender rules and clauses
Awareness about features of IREPS, Tender opening and
7 processing, Opening of tenders, Tabulation statement & Briefing 03
note
Finalization of tenders - Technical evaluation, Tender committee
8 nomination, Tender committee deliberations and 03
recommendations
9 Awarding of Contract, Acceptance of tender, Issue of letter of
03
acceptance & Starting of contract
Execution of Contract- Fulfillment of contract obligations,
10 Inspection of work, Record of work done, Payment to the contract 03
& Monitoring of progress, Shramik kalyan portal
11 Vigilance angle to contracts, Do’s and Don'ts, Arbitration 02
Case Studies, cases in workshops, open line & Diesel Sheds,
12 04
Mechanized Laundry Contract under BOOT model
13 Review 02
Total 36
Page 30 of 118
SUBJECT NAME ACCIDENT & DISASTER MANAGEMENT
SUBJECT CODE MRT-08
MODULE MSE, MJR & MJI
TIME IN
SL NO. TOPIC
HRS
Definition of Disaster, Types of Accidents, Accident Manual, Rail
1 02
wheel interaction
2 Permanent way parameters
03
3 Readings in permanent way
4 Rolling stock parameters
04
5 Readings in rolling stock
6 Signal aspects to be recorded at the accident site 02
7 Recording of track, rolling stock 02
8 Role of supervisors at the accident site 02
Features of Disaster Management, Disaster Management Plan of
9 02
Zonal Railways
Disaster Management Equipment in Railways, Composition and
10 02
upkeep of ART/ARMV/SPART/ 140T Crane, Hooter Codes
11 Civil Defense & First-Aid after an accident 03
12 Duties of Officials at Accident Site 02
13 Rescue Extrication Techniques & Fire Fighting 02
14 Rescue Techniques- Medical Relief, Golden Hour, CPR 03
15 Duties of on-board staff at accident site 02
Operation of 140T Crane at Accident Sites, Major Systems of
16 02
Cranes
17 Demonstration of HRE/ HRD, Mock Drill 03
Total 36
Page 31 of 118
SUBJECT NAME MANAGERIAL SKILLS
SUBJECT CODE MRT-09
MODULE MSE, MJR & MJI
TIME IN
SL NO. TOPIC
HRS
1 Leadership 12
2 Motivation 06
3 Communication Skills 09
4 Time Management 03
5 Stress management 03
6 Ethical Decision-making 03
Computer Applications: Word, Excel, Power Point; including
7 09
Hands on in Computer Lab
8 Project management Concepts 15
9 Teamwork & Teambuilding 06
10 Negotiations 06
Total 72
Page 32 of 118
SUBJECT NAME Welding and Non-Destructive Testing
SUBJECT CODE MRT-10
MODULE MJR & MJI-W
TIME IN
SL NO. TOPIC
HRS
Welding - Principle and applications in various fabrication work,
1 different types of Welding Processes, Weldability of material (MS 03
& SS) and Welding metallurgy
Arc welding process and principle, tools required for Arc welding,
2 Setting welding current & voltage, Maintenance of welding 06
machine, SS Welding, Welding of dissimilar metals
Job preparation, Electrodes, Electrode selection for difference
3 03
welding work, Types of Joints, Welding Symbols used in Drawings
4 Safety precautions, Do’s & Don'ts 02
Special Welding Techniques: C02 welding- Method, precautions
5 etc.; C.I. welding; MIG & TIG welding work; seam welding; sub 06
merged arc welding; flash butt welding
Different Cutting and Gauging Processes, Plasma Cutting:
6 03
Electrode Arc Cutting, OA Cutting, Laser Cutting
Introduction to NDT, Various types of NDT method like LPT,
7 04
Magna flux, Radiography, Ultra Sonic Flaw Detection etc
8 Defects & remedies in welding 02
9 Robotic Welding, Welding Automation 02
10 ISO 3834, WPS Preparation and Welder Qualification 03
11 Review 02
Total 36
Page 33 of 118
SUBJECT NAME Train Operation with Signaling
SUBJECT CODE MRT-11
MODULE MSE, MJR & MJI-C&D
TIME IN
SL NO. TOPIC
HRS
1 Organization of Operating Department
2 G&SR
3 Safety rules
4 Classification of stations
5 Systems of working
6 Essentials of Absolute automatic one train only system
7 Signals of all types
8 Working of Control Organization
9 Abnormal working
10 Line capacity & Important operating statistics
11 Accident Management
12 Working of Commercial Department
13 Customer Care
14 Review
Total 72*
Page 34 of 118
SUBJECT NAME Integrated Course at IRIMEE
SUBJECT CODE MRT-12
MODULE MSE, MJR
TIME IN
SL NO. TOPIC (*)
WEEKS
1 Mechatronics
2 Reliability Engineering
3 Operation and Maintenance of Crane
4 Advancement in Rolling Stock Technology
5 Welding and Non-Destructive Testing
6 E-office & Manual of Office procedure
Total 04
(*): These topics are only illustrative. Exact course content and detailing
would be done by IRIMEE.
Page 35 of 118
SUBJECT NAME INTRODUCTION TO ROLLING STOCK
SUBJECT CODE MRT-13
MODULE MJI
TIME IN
SL NO. TOPIC
HRS
Types of Coach and their nomenclature, Codal life, Transportation
1 03
Codes, Coach numbering system
2 Introduction of Coach Shell: ICF and LHB Coach 02
3 Wheel set- wheel, axle & bearings 04
Introduction of Different types of Bogie for Rolling Stock and
4 06
Suspension system including Air Suspension
Types of Draw and Buffing Gears in Coaches and Wagons: An
5 06
Introduction
6 Air & EP Brake system; Brake riggings 09
Furnishing items: ICF and LHB, EMU/MEMU coaches, Safety &
7 04
amenity fittings
8 Maintenance practice in coaching stock 03
Types of wagon stock, their nomenclature, Codal life,
9 03
Transportation Codes, Wagon Numbering System
10 Types of bogies in wagon stock 03
11 Features of special wagons/latest wagons 03
12 Pattern of freight train examination 03
Diesel locomotives - types,
13 03
Introduction of Electric Loco, EMU/MEMU & Train-Sets
Important systems in a diesel locomotive: Fuel oil, lube oil, cooling
14 15
water, turbo supercharging & brake system
Electrical control system in Locomotives and Train-
15 06
Sets/EMU/MEMU
Latest development in Rolling Stock including Locomotives and
16 06
Train-Sets
17 DEMU: Power and Trailing cars, important features and systems 05
18 SPART- Introduction, Basic arrangements, importance. 01
Weighbridge, WILD and other way side monitoring systems:
19 03
Overview
20 Visit to model room/coaching/wagon depot/workshop & loco shed 14
21 Review 06
Total 108
Page 36 of 118
SUBJECT NAME COMPUTER AWARENESS
SUBJECT CODE MRT-14
MODULE MJI, MJP
TIME IN
SL NO. TOPIC
HRS
Introduction to Computers and Application of Computers/Windows,
1 06
CMM, FMM
2 MS Word 09
3 MS Excel 09
4 MS Power Point 06
5 Internet usage 03
6 Review 03
Total 36
Page 37 of 118
SUBJECT NAME TECHNICAL ENGLISH
SUBJECT CODE MRT-15
MODULE MJI
TIME IN
SL NO. TOPIC
HRS
1 Communication Vocabulary 03
2 Grammar - Important terms 06
3 Common Errors 06
4 Precis writing, Expansion of given idea 03
5 Comprehension 03
6 Official Correspondence 03
7 Business Correspondence 03
8 Social Correspondence 03
9 General Report Writing 03
10 Technical Report Writing 03
Total 36
Page 38 of 118
SUBJECT NAME INDUSTRIAL SAFETY, FIRST AID & FIRE FIGHTING
SUBJECT CODE MRT - 16
MODULE MJP- C, D & W
DURATION 3 Days
SL NO. TOPIC
Causes of fire;
1
Identification of unsafe conditions and unsafe acts
2 Identifying and handling of various types of fire extinguishers
3 Precautions to be taken while extinguishing fire
Render first aid to the burn injuries;
4
Render first aid to persons affected by suffocation; Communication
5 Scope and Rules of first Aid; Structure and function of body
General idea about circulation of blood;
6
Wound & Hemorrhages; Dressing & Bandages
7 Shock & its management; Asphyxia & Artificial respiration
Injuries to bones & joints - fractures; Unconsciousness and General rules for
8
the treatments of unconsciousness person
Practical demonstration of Transport of injured persons, stretcher exercises,
9
preparing and blanketing stretcher
Principles of Accident, Causation & Its Prevention, Unsafe Acts & Unsafe
10
Conditions
11 House Keeping & Material Handling, 5S
12 Safety on Small Tools and Electrical Appliances
13 Use of PPE
14 Role of Supervisors on Safety, Accident Reporting & Investigations
15 Review
Page 39 of 118
SUBJECT NAME ACCIDENT & DISASTER MANAGEMENT
SUBJECT CODE MRT - 17
MODULE MJP- C, D & W
DURATION 2 Days
SL NO. TOPIC
Definition of Disaster, Types of Accidents, Accident Manual, Rail wheel
1
interaction
2 Permanent way parameters, Readings in permanent way
3 Rolling stock parameters, Readings in rolling stock
4 Signal aspects to be recorded at the accident site
5 Recording of track, Rolling Stock
6 Role of supervisors at the accident site
Disaster Management Equipment in Railways, Composition and upkeep of
7
ART/ARMV/SPART/ 140T, Hooter Codes
8 Civil Defense & First-Aid after an accident
9 Duties of Officials at Accident Site
10 Rescue Extrication Techniques & Fire Fighting
11 Rescue Techniques- Medical Relief, Golden Hour, CPR
12 Duties of on-board staff at accident site
Page 40 of 118
SUBJECT NAME SUPERVISORY SKILLS
SUBJECT CODE MRT - 18
MODULE MJP- C, D & W
DURATION 3 Days
SL NO. TOPIC
1 Leadership & Leadership styles
2 Motivation
3 Communication Skills
4 Time Management
5 Stress management
6 Interpersonal Skills
7 Ethics
Page 41 of 118
SUBJECT NAME TECHNICAL ENGLISH
SUBJECT CODE MRT-19
MODULE MJP- C, D & W
DURATION 3 Days
SL NO. TOPIC
1 Communication Vocabulary
2 Grammar - Important terms
3 Common Errors
4 Official Correspondence
5 Business Correspondence
6 General Report Writing
7 Technical Report Writing
Page 42 of 118
SUBJECT NAME APPLIED MECHANICS
SUBJECT CODE MET-01
MODULE MJI
TIME IN
SL NO. TOPIC
HRS
1 Scalars and Vectors 01
2 Composition & resolution of forces 05
3 Equilibrium 03
4 Parallel forces & Couples 03
5 Plane motion 03
6 Newton’s laws of motion 06
7 Collision of Elastic bodies 04
8 Motion of connected bodies 04
9 Work, power and Energy 03
10 Friction 06
11 Motion of Rotation 03
12 Motion along circular path 03
13 Simple Harmonic Motion 03
14 Simple lifting machines 03
15 Review 04
Total 54
Page 43 of 118
SUBJECT NAME HYDRAULICS
SUBJECT CODE MET-02
MODULE MJI
TIME IN
SL NO. TOPIC
HRS
1 Introduction to Basic concepts 02
2 Fluid Pressure 02
3 Hydrostatics 02
4 Buoyancy & Floatation 02
5 Hydro Kinematics 02
6 Bernoulli’s Theorem 02
7 Flow through Orifices & mouth pieces 02
8 Impact of jets 02
9 Water wheels 02
10 Impulse Turbines 02
11 Reaction Turbines 02
12 Performance of turbines 02
13 Reciprocating Pumps 02
14 Centrifugal Pumps 02
15 Performance of pumps 02
16 Pumping Devices 02
17 Review 04
Total 36
Page 44 of 118
SUBJECT NAME MANUFACTURING PROCESSES
SUBJECT CODE MET-03
MODULE MJI
TIME IN
SL NO. TOPIC
HRS
1 Production of metals 06
2 Hot and cold working 06
3 Smithy and forging 03
4 Foundry 03
5 Metal Joining 12
Metal Cutting Operations using different machines: Lathe, Drilling
6 machine, Shaper and Planner, Grinding, Milling (CNC& non-CNC) 12
etc.
7 Machining Operations in Wheel Shop 09
8 Basics of Metrology and Calibration 06
9 Physical Testing of materials (DT & NDT) 06
10 Un-conventional machines (Laser, Electron Beam etc) 06
11 Review 03
Total 72
Page 45 of 118
SUBJECT NAME ENGINEERING DRAWING
SUBJECT CODE MET-04
MODULE MJI
TIME IN
SL NO. TOPIC
HRS
1 Introduction about Engg. Drg. 01
2 Drawing Board, Instruments & its use 01
3 Lettering & Types of Lines 03
4 Dimensioning systems 03
5 Geometrical Constructions 03
6 Scales 06
7 Engineering curves 06
Principle of Projection - Projection of Points, Lines, Planes &
8 18
Solids
9 Section of Solids 09
10 Isometric Projections of solids & M/C Components 08
11 Orthographic views of Solids & M/C Components 08
12 Review 06
Total 72
Page 46 of 118
SUBJECT NAME ELECTRICAL ENGINEERING
SUBJECT CODE MET-05
MODULE MJI
TIME IN
SL NO. TOPIC
HRS
1 Current & Ohms Law 02
2 Simple DC Circuits & Network Analysis 04
3 Magnetism & Electromagnetism 03
4 Electromagnetic Induction 03
5 D.C. Generator & D.C Motor 04
6 Fundamentals of A.C 03
7 Single Phase A.C. Circuit & Three Phase A.C. Circuit 06
8 Alternators 02
9 Induction motors - Single phase & three phase 06
10 Transformer 03
11 Batteries, electrical instruments & measurements 04
Introduction to electrical energy generation, electrical safety,
12 04
energy conservation
13 Basic Electronics 06
14 Review 04
Total 54
Page 47 of 118
SUBJECT NAME STRENGTH OF MATERIALS
SUBJECT CODE MET-06
MODULE MJI
TIME IN
SL NO. TOPIC
HRS
1 Introduction about materials & its properties 02
2 Simple stress and strain 12
3 Elastic constants 06
4 Centre of gravity 03
5 Moment of inertia 07
6 Shear force & bending Moment of beams 20
7 Stresses in beams 08
8 Torsion of shafts 08
9 Review 06
Total 72
Page 48 of 118
HEAT ENGINES & THERMODYNAMICS, REFRIGERATION &
SUBJECT NAME
AIR CONDITIONING
SUBJECT CODE MET-07
MODULE MJI
TIME IN
SL NO. TOPIC
HRS
1 Introduction 02
2 Properties of Gases, Laws of Thermodynamics 06
3 Thermodynamic process of perfect gases 04
4 Heat and mass transfer 06
5 Steam 03
6 Air cycles 03
7 Internal combustion engines 06
8 IC Engine Systems 04
9 Testing of IC Engine 02
10 Compressors 04
11 Refrigerants 04
12 Refrigeration Cycles 06
13 Properties of moist air 06
14 Psychrometry of Air-Conditioning Process, Load calculation 08
15 Application of Air-conditioning in Railways 04
16 Reviews. 04
Total 72
Page 49 of 118
SUBJECT NAME THEORY OF MACHINES
SUBJECT CODE MET-08
MODULE MJI
TIME in
SL NO. TOPIC
HRS.
1 Mechanisms 04
2 Brakes and dynamometers 04
3 Belt, rope and chain drive 04
4 Gears 06
5 Clutches 02
6 Governor 04
7 Flywheel and turning moment diagram 04
8 Balancing of masses 04
9 Review 04
Total 36
Page 50 of 118
SUBJECT NAME MATERIAL SCIENCE
SUBJECT CODE MET-09
MODULE MJI
TIME IN
SL NO. TOPIC
HRS
1 Introduction 02
Solid phases, phase diagrams and phase transformation, Iron
2 03
carbon equilibrium diagram
3 Heat treatment 06
4 Types of alloy steels 02
5 Non-ferrous metals 02
6 Paint, Enamel, Varnishes and lacquers 02
7 Classification of railway materials 02
8 Plastic and synthetic materials 02
9 Review 03
Total 24
Page 51 of 118
SUBJECT NAME MACHINE DESIGN AND DRAWING
SUBJECT CODE MET-10
MODULE MJI
TIME IN
SL NO. TOPIC
HRS
1 Introduction about Design principle 02
2 Design of keys 02
3 Design & Drawing of screw thread 04
4 Design of coupling 04
5 Design of welded joints 03
6 Design & Drawing of cotter& knuckle joints 04
7 Design & Drawing of Riveted joint 04
8 Design & Drawing of CAM profile 04
9 Design of Coil springs 03
10 Design of Laminated springs 02
11 Limits, Fits & Tolerance 04
12 Orthographic & Isometric Drawing of machine components 02
13 Assembly Drg of Foot Step Bearing 02
14 Assembly Drg of Plummer Block 02
15 Assembly Drg of Screw Jack 02
16 Assembly Drg of Tail Stock 02
17 Review 02
Total 48
Page 52 of 118
SUBJECT NAME INDUSTRIAL ENGINEERING
SUBJECT CODE MET-11
MODULE MJI
TIME IN
SL NO. TOPIC
HRS
1 Introduction 02
2 Method Study 04
3 Principle of Motion Economy 02
4 Plant Layout 02
5 Work Measurement 06
6 Network Techniques 06
7 Exercise on Network 02
8 Incentive Schemes in Railway Workshops 06
9 Job Evaluation and Merit Rating 03
10 Review 03
Total 36
Page 53 of 118
SUBJECT NAME MANUFACTURING PROCESS
SUBJECT CODE MET-12
MODULE MJP- C, D & W
DURATION 04 Days
SL NO. TOPIC
1 Production of metals
2 Hot and cold working
3 Smithy and forging
4 Foundry
5 Metal Joining
Metal Cutting Operations using different machines: Lathe, Drilling machine,
6
Shaper and Planner, Grinding, Milling (CNC& non-CNC) etc.
7 Machining Operations in Wheel Shop
8 Basics of Metrology and Calibration
9 Physical Testing of materials (DT & NDT)
10 Un-conventional machines (Laser, Electron Beam etc.)
11 Review
Page 54 of 118
SUBJECT NAME INDUSTRIAL ENGINEERING
SUBJECT CODE MET-13
MODULE MJP- C, D & W
DURATION 01 Days
SL NO. TOPIC
1 Introduction
2 Method Study
3 Principle of Motion Economy
4 Plant Layout
5 Work Measurement
6 Incentive Schemes in Railway Workshops
7 Job Evaluation and Merit Rating
Page 55 of 118
SUBJECT NAME ENGINEERING DRAWING
SUBJECT CODE MET-14
MODULE MJP- C, D & W
DURATION 02 Days
SL NO. TOPIC
1 Introduction about Engg. Drg.
2 Drawing Board, Instruments & its use
3 Lettering & Types of Lines
4 Dimensioning systems
5 Geometrical Constructions
6 Scales
7 Engineering curves
8 Principle of Projection - Projection of Points, Lines, Planes & Solids
Page 56 of 118
Index for Stream wise subjects
Subject Page
Sl. No. Name of Subject Module
Code No.
1 C & W Theory - 01 MCT - 01 MSE-C, MJR-C & MJI-C 58
2 C & W Theory - 02 MCT - 02 MSE-C, MJR-C & MJI-C 59-60
3 C & W Theory - 03 MCT - 03 MJP-C 61
4 C & W Theory - 04 MCT - 04 MJP-C 62
5 Diesel Locomotive Theory MDT - 01 MSE-D, MJR-D, MJI-D 63
(Common) - 01
6 Diesel Locomotive Theory MDT - 02 M MSE-D, MJR-D 64
(Mechanical) – 02 M
7 Diesel Locomotive Theory MDT - 02 E MSE-D, MJR-D 65
(Electrical) – 02 E
8 Diesel Locomotive Theory MDT - 03 M MJI-D 66
(Mechanical) – 03 M
9 Diesel Locomotive Theory MDT - 04 M MJI-D 66
(Mechanical) – 04 M
10 Diesel Locomotive Theory MDT - 03 E MJI-D 67
(Electrical) – 03 E
11 Diesel Locomotive Theory MDT - 04 E MJI-D 67
(Electrical) – 04 E
12 Diesel Locomotive Theory MDT - 05 M MJP-D 68
(Mechanical) – 05 M
13 Diesel Locomotive Theory MDT - 05 E MJP-D 69
(Electrical) – 05 E
14 Workshop Theory - 01 MWT - 01 MSE-W, MJR-W 70
15 Workshop Theory - 02 MWT - 02 MSE-W, MJR-W 71-72
16 Workshop Theory - 03 MWT - 03 MJI-W 73-74
17 Workshop Trade Theory - 04 MWT - 04 MJI-W 75-77
18 Workshop Theory - 05 MWT - 05 MJP-W 78-79
Page 57 of 118
SUBJECT NAME C & W THEORY-01
SUBJECT CODE MCT-01
MODULE MSE-C, MJR-C, MJI-C
Duration
Sl. No. Topic
in Hours
Design, Repair & Maintenance of Shell: ICF, LHB, MEMU/EMU
coaches and all variants like double decker, Tejas, Gatiman,
1 18
Hamsafar, Dindayalu, Project Swarn & Project Utkristh, Train-sets
etc.
2 Wheel & its defects, Wheel shelling in LHB coaches 06
3 Axles & bearings of all rolling stocks including MSU 06
Air Brake System: Components, BMBC, EP brake, WSP, Pipe
4 32
joints, Testing of coach brake, Loco capability test, continuity test
Repair and maintenance of Passenger Amenities and Safety
5 06
fittings
Bogie and Suspension system including Air Suspension: Failure &
6 12
remedial features, Repair and Maintenance, FIBA
Couplings & Buffers, IRS, CBC, Schaku, Dellnor, BDG: Design,
7 18
repair and maintenance
Train Examination -Coaches: Maintenance schedules, Revised
8 08
RPC-IV, Issue of BPC, CMM, En-route trouble shooting
Infrastructure requirement for coach maintenance: Pit lay-out,
9 Sick line lay-out, Rake link, M&P Pit occupation chart, automated 18
coach washing plant, warranty claims of coaching items
10 IRCA Part IV, Modifications, TSOs, CAIs, Technical Pamphlets 06
11 Latest JPOs in Coaching Stock 02
12 Visit to major coaching depot 06
13 Review 06
Total 144
Page 58 of 118
SUBJECT NAME C & W THEORY-02
SUBJECT CODE MCT-02
MODULE MSE-C, MJR-C, MJI-C
Duration
Sl. No. Topic
in Hours
Train lighting & Air-Conditioning: Maintenance of Battery and
Battery box, RMPU, Lay-out of TL & AC equipment in Non-AC/AC
1 24
and Power cars, Alternator, Invertor, RRU, IVC (inter vehicle
couplers), SG, EOG, HOG
Toilet Systems: WRA and plumbing system, Bio toilets & Bio-
2 06
vacuum toilets
EnHM: MCC, OBHS, CTS, Pest control, Rodent control & Bed
bugs control, Linen distribution, laundry: BOOT Laundry
3 Equipment, disposal of solid waste, quick watering system, 24
automatic coach washing plant, waste water recycling, Station
cleaning, cleaning of IT device, electrical equipment
Design features of various wagons including Stainless steel
4 wagons, Aluminum wagons, Higher Axle load wagons, BOBRN 18
Wagon including its door opening mechanism
New pattern of Train examination of goods stock-
5 CC/Premium/End to End, long haul, heavy haul, Issue of BPC, e- 06
BPC, FMM
6 Wagon manufacturing - use of huck bolts 06
7 ODC: classification, procedure for sanction, movement guidelines 06
8 Container wagons-BLC Train operation and maintenance practice 06
9 IRCA Part III 12
10 Repair & maintenance of goods stock-ROH 12
11 Tank Wagons - repairs & maintenance 06
Twin pipe air brake system in wagon, BMBS in wagon, Brake
12 12
Binding- Causes & remedies
13 Train Parting - Causes & remedies 12
Tippler operation, Silo loading; recovery of damages during
14 loading unloading from private siding, warranty claims of wagon 06
items
15 Accident Relief Train 06
16 Derailment Mechanism 06
17 Accident Investigation, CRS Inquiry 06
18 Disaster Management - Role of Supervisors 15
19 Prevention of accident on C&W account 12
20 ART/MFD/SPART/140T Crane Maintenance 09
Layout of Coaching & goods stock yard and its infrastructural
21 12
facilities
Weigh bridge: AMC, test special, Calibration, action to be taken in
22 06
case of overloading
WILD, Hot Box detector, Track side bogie monitoring system,
23 06
Action to be taken on reporting
Page 59 of 118
Duration
Sl. No. Topic
in Hours
24 Depot stores management 06
25 Marshaling of trains 06
Role of Supervisors to minimize sick figures/coach
26 06
detachment/ineffective %
27 Visit to major coaching depot 06
28 Visit to major goods depot 18
29 Review 12
Total 288
Page 60 of 118
SUBJECT NAME C & W THEORY-03
SUBJECT CODE MCT-03
MODULE MJP-C
Duration
Sl. No. Topic
in Hours
1 Overview of C&W organization 03
Design, Repair & Maintenance of Shell: ICF, LHB, MEMU/EMU
coaches and all variants like double decker, Tejas, Gatiman,
2 06
Hamsafar, Dindayalu, Project Swarn & Project Utkristh, Train-Sets
etc.
Air Brake System: Components, BMBC, EP brake, WSP, Pipe
3 09
joints, Testing of coach brake, Loco capability test, continuity test
Twin pipe air brake system in wagon, BMBS in wagon, Brake
4 03
Binding -Causes & remedies
5 Repair and maintenance of Passenger Amenities and Safety fittings 03
Bogie and Suspension system including Air Suspension: Repair and
6 08
Maintenance, FIBA
Wheel & its defects, Wheel shelling in LHB coaches, Axles &
7 06
bearings of all rolling stocks including MSU
Couplings & Buffers, IRS, CBC, Schaku, Dellnor, BDG: Design,
8 06
repair and maintenance
9 Train Parting - Causes & remedies 03
Train Examination -Coaches: Maintenance schedules, Revised
10 03
RPC-IV, Issue of BPC, CMM, En-route trouble shooting
IRCA Part IV, Modifications, TSOs, CAIs, Technical Pamphlets,
11 03
Latest JPOs in Coaching Stock
Train lighting & Air-Conditioning: Maintenance of Battery and
Battery box, RMPU, Lay-out of TL & AC equipment in Non-AC/AC
12 16
and Power cars, Alternator, Invertor, RRU, IVC (inter vehicle
couplers), SG, EOG, HOG
Toilet Systems: WRA and plumbing system, Bio-toilets & Bio-
13 03
vacuum toilets
Total 72
Page 61 of 118
SUBJECT NAME C & W THEORY-04
SUBJECT CODE MCT-04
MODULE MJP-C
Duration
Sl. No. Topic
in Hours
Design features of various wagons including Stainless steel
1 wagons, Aluminum wagons, Higher Axle load wagons, BOBRN 06
Wagon including its door opening mechanism
New pattern of Train examination of goods stock-
2 CC/Premium/End to End, long haul, heavy haul, Issue of BPC, e- 03
BPC, FMM
3 Wagon manufacturing - use of huck bolts 03
4 ODC: classification, procedure for sanction, movement guidelines 03
5 Container wagons-BLC Train operation and maintenance practice 03
6 IRCA Part III 03
7 Repair & maintenance of goods stock-ROH 03
8 Tank Wagons - repairs & maintenance 03
9 Accident Relief Train 03
10 Derailment Mechanism 03
11 Accident Investigation, CRS Enquiry 03
12 Disaster Management - Role of Supervisors 03
13 Prevention of accident on C&W account 03
14 ART/MFD/SPART/140 T Crane Maintenance 03
WILD, Hot Box detector, Track side bogie monitoring system,
15 03
Action to be taken on reporting
16 Depot stores management 03
17 Marshalling of trains 03
Role of Supervisors to minimize sick figures/coach
18 03
detachment/ineffective %
Weigh bridge: AMC, Test special, Calibration, action to be taken in
19 03
case of overloading
EnHM: MCC, OBHS, CTS, Pest control, Rodent control & Bed
bugs control, Linen distribution, laundry: BOOT Laundry
20 Equipment, disposal of solid waste, quick watering system, 09
automatic coach washing plant, waste water recycling, Station
cleaning, cleaning of IT device, electrical equipment
Layout of Coaching & goods stock yard and its infrastructural
21 03
facilities
Total 72
Page 62 of 118
SUBJECT NAME DIESEL LOCOMOTIVE THEORY (Common.) - 01
SUBJECT CODE MDT-0l
MODULE MSE-D, MJR-D, MJI-D
Duration
Sl. No. Topic
in Hours
Lay out of Locomotives, Single/Dual Cab design, Types of I.C.
1 06
Engines and working, classification
Traction Machine, Tractive effort-speed characteristics and co
2 06
efficient of Adhesion (Alco & HHP)
Supercharging principles, methods and various testing parameters,
3 06
Air and Computer control brake system (Alco & HHP)
Fuel system - components, function, defects and remedy, Fuel
4 06
injection system (Alco & HHP)
Lube oil system - components, function, defects and remedy (Alco
5 06
& HHP)
Cooling water system - components, function, defects and remedy,
6 06
Radiator fan - principle, operation and maintenance (Alco & HHP)
Layout of shop and shed, Schedule of maintenance (Alco & HHP),
7 06
Shed management, Record keeping, Outages, Super checking
Loco maintenance procedure; Bogies- types, load transfer,
transmission of TE, suspension system; Cattle guard, gear case,
8 06
wheel profile, specification & defect, coupling, bearing fitment etc.
(Alco & HHP)
9 REMMLOT and Vigilance Control Device 06
10 GE locos- introduction, features, advantages etc 06
Various types of Transmission, feature of an Ideal transmission in
11 12
Diesel Loco, AC-DC, AC-AC transmission
Various rotating equipment such as TA, TM, EG/CA, AG, DB
Blower, Fuel booster pump motor - Description
12 18
/Overhauling/Repair/Testing, common problems & remedy (Alco &
HHP), ECC & CCEM in Alco
Excitation systems and Dynamic brake system (Alco & HHP),
13 12
Transition system - circuit analysis, defects and remedy for Alco
Microprocessor based controls, APU, DEMU DPC, Distributed
14 12
Power Control System (DPCS)
15 Types of governors, overhauling procedure, testing methods 12
Various safety & Misc items- Cab equipment, Driver seat, Wiper,
16 Horn, Head light, Sanding equipment, Hand brake, Emergency 12
switches and alarm fitted in Loco - working principles (Alco & HHP)
Testing of Engines - Dry-run-Test, Blow-bye test, Random test,
17 06
Load Box testing, MU operation testing
Total 144
Page 63 of 118
SUBJECT NAME DIESEL LOCOMOTIVE THEORY(MECHANICAL)-02 M
SUBJECT CODE MDT-02 M
MODULE MSE-D, MJR-D
Duration
Sl. No. Topic
in Hours
Power pack – Cylinder head, cylinder liner, connecting rod, cam
1 48
shaft etc (Alco & HHP)
Supercharging principles, methods and various testing parameters,
2 36
Air and Computer Control Brake
Air compressor, types, function and overhauling procedures; Air-
3 30
Dryer
Fuel system – components, function, defects and remedy, Fuel
4 22
injection system (Alco & HHP)
Lube oil system – components, function, defects and remedy (Alco
5 28
& HHP)
Cooling water system – components, function, defects and
6 remedy, Radiator fan – principle, operation and maintenance (Alco 22
& HHP)
Layout of shop and shed, Schedule of maintenance (Alco & HHP),
7 18
Shed management, Record keeping, Outages, Super checking
Loco maintenance procedure; Bogies- types, load transfer,
transmission of TE, suspension system; Cattle guard, gear case,
8
wheel profile, specification & defect, coupling, bearing fitment etc. 30
(Alco & HHP)
9 GE loco- Mechanical System 12
10 DEMU-DPC Power pack and its mechanical system 24
Safety & Misc items- Cab equipment, Driver seat, Sanding
11 06
equipment, Hand brake etc
Testing of Engines - Dry-run-Test, Blow-bye test, Random test,
12 12
Load Box testing
Total 288
Page 64 of 118
SUBJECT NAME DIESEL LOCOMOTIVE THEORY(ELECTRICAL)-02 E
SUBJECT CODE MDT-02 E
MODULE MSE-D, MJR-D
Duration
Sl. No. Topic
in Hours
Various types of Transmission, feature of an Ideal transmission in
1 12
Diesel Loco, AC-DC, AC-AC transmission
Various rotating equipment such as TA, TM, EG/CA, AG, DB
Blower, Fuel booster pump motor - Description
2 90
/Overhauling/Repair/Testing, common problems & remedy (Alco &
HHP), ECC & CCEM in Alco
Excitation systems and Dynamic brake system, Transition system
3 48
- circuit analysis, defects and remedy for Alco
Microprocessor based controls, APU, Distributed Power Control
4 System, Safety devices 42
Flasher light, horn, Wiper, head light, cab light etc.
5 Types of governors, overhauling procedure, testing methods 06
6 Emergency switches and alarm fitted in Loco - working principles 06
7 Testing of Engines - Load Box testing, MU operation testing 12
8 DEMU-DPC Electrical and control system, EP Brake, SPART 24
9 GE Loco- Electrical System 12
Excitation systems, Dynamic brake system, circuit analysis,
10 36
defects and remedy for HHP loco
Total 288
Page 65 of 118
SUBJECT NAME DIESEL LOCOMOTIVE THEORY(MECHANICAL)-03 M
SUBJECT CODE MDT-03 M
MODULE MJI-D
Duratio
Sl. No. Topic n in
Hours
Power pack - Cylinder head, cylinder liner, connecting rod. cam
1 48
shaft etc. (Alco & HHP)
Supercharging principles, methods and various testing parameters,
2 42
Air and CCB (Alco & HHP)
Air compressor types, function and overhauling procedures (Alco &
3 30
HHP); Air-Dryer
Fuel system - components, function, defects and remedy, Fuel
4 24
injection system (Alco & HHP)
Total 144
Duratio
Sl. No. Topic n in
Hours
Lube oil system - components, function, defects and remedy (Alco
1 24
& HHP)
Cooling water system - components, function, defects and remedy,
2 18
Radiator fan - principle, operation and maintenance (Alco & HHP)
Layout of shop and shed, Schedule of maintenance (Alco & HHP),
3 18
Shed management, Record keeping, Outages, Super checking
Loco maintenance procedure; Bogies- types, load transfer,
transmission of TE, suspension system; Cattle guard, gear case,
4 30
wheel profile, specification & defect, coupling, bearing fitment etc.
(Alco & HHP)
5 GE loco – Mechanical System 12
6 DEMU DPC – Power pack and mechanical System 24
Safety & Misc items- Cab equipment, driver seat, sanding
7 06
equipment, Hand brake etc
Testing of Engines - Dry-run-Test, Blow-bye test, Random test,
8 12
Load Box testing
Total 144
Page 66 of 118
SUBJECT NAME DIESEL LOCOMOTIVE THEORY(ELECTRICAL)-03 E
SUBJECT CODE MDT-03 E
MODULE MJI-D
Duratio
Sl. No Topic n in
Hours
Various types of Transmission, feature of an ideal transmission in
1 12
Diesel Loco, AC-DC, AC-AC transmission
Various rotating equipment such as TA, TM, EG, AG, DB Blower,
CCEM, ECC, Fuel booster motor-
2 38
Description/Overhauling/Repair/Testing, common problems &
remedy for Alco loco
3 Excitation systems for Alco and HHP loco 30
Various rotating equipment such as TA, CA, AG, DB blower,
4 starting motor, DB grid motor, Radiator fan motor, TCC Blower, FP 40
motor etc for HHP loco
DEMU-DPC Electrical and control system, EP Brake, train lighting,
5 24
SPART
Total 144
Duratio
SI. No Topic n in
Hours
Dynamic brake system, Transition system - circuit analysis, defects
1 30
and remedy for Alco
Microprocessor based controls, APU, REMMLOT, Distributed
2 30
Power Control System (DPCS)
3 Types of governors, overhauling procedure, testing methods 12
Various safety devices, Horn, Head light, Wiper, Emergency
4 12
switches and alarm fitted in Loco - working principles
5 Testing of Engines - Load Box testing, MU operation testing 12
Dynamic brake system, circuit analysis defect and remedy for HHP
6 30
loco
7 GE Loco- electrical machines and control system 18
Total 144
Page 67 of 118
SUBJECT NAME DIESEL LOCOMOTIVE THEORY(MECHANICAL)-5M
SUBJECT CODE MDT-05 M
MODULE MJR-D
DURATION 24 Days
Duration
SI. No. Topic
in Hours
Power pack – Cylinder head, cylinder liner, connecting rod, cam
1 24
shaft etc (Alco & HHP)
Supercharging principles, methods and various testing parameters,
2 18
Air and Computer Control Brake
Air compressor, types, function and overhauling procedures; Air-
3 12
Dryer
Fuel system – components, function, defects and remedy, Fuel
4 12
injection system (Alco & HHP)
Lube oil system – components, function, defects and remedy (Alco
5 12
& HHP)
Cooling water system – components, function, defects and
6 remedy, Radiator fan – principle, operation and maintenance (Alco 12
& HHP)
Layout of shop and shed, Schedule of maintenance (Alco & HHP),
7 12
Shed management, Record keeping, Outages, Super checking
Loco maintenance procedure; Bogies- types, load transfer,
transmission of TE, suspension system; Cattle guard, gear case,
8 12
wheel profile, specification & defect, coupling, bearing fitment etc.
(Alco & HHP)
9 GE loco- Mechanical System 08
10 DEMU-DPC Power pack and its mechanical system 12
Safety & Misc items- Cab equipment, Driver seat, Sanding
11 04
equipment, Hand brake etc
Testing of Engines - Dry-run-Test, Blow-bye test, Random test,
12 06
Load Box testing
Total 144
Page 68 of 118
SUBJECT NAME DIESEL LOCOMOTIVE THEORY (ELECTRICAL)-5E
SUBJECT CODE MDT-05 E
MODULE MJR-D
DURATION 24 Days
Duratio
Sl. No Topic n in
Hours
Various types of Transmission, feature of an Ideal transmission in
1 06
Diesel Loco, AC-DC, AC-AC transmission
Various rotating equipment such as TA, TM, EG, AG, DB Blower,
CCEM, ECC, Fuel booster motor-
2 18
Description/Overhauling/Repair/Testing, common problems &
remedy for Alco loco
3 Excitation systems for Alco and HHP loco 12
Various rotating equipment such as TA, CA, AG, DB blower,
4 starting motor, DB grid motor, Radiator fan motor, TCC Blower, FP 18
motor etc for HHP loco
Dynamic brake system, Transition system - circuit analysis, defects
5 12
and remedy for Alco
Microprocessor based controls, APU, REMMLOT, Distributed
6 18
Power Control System (DPCS)
7 Types of governors, overhauling procedure, testing methods 08
Various safety devices, Horn, Head light, Wiper, Emergency
8 08
switches and alarm fitted in Loco - working principles
9 Testing of Engines - Load Box testing, MU operation testing 12
Dynamic brake system, circuit analysis defect and remedy for HHP
10 12
loco
11 GE Loco- electrical machines and control system 08
DEMU-DPC Electrical and control system, EP Brake, train lighting,
12 12
SPART
Total 144
Page 69 of 118
SUBJECT NAME WORKSHOP THEORY -01
SUBJECT CODE MWT-01
MODULE MSE-W, MJR-W
Duration
Sl. No Topic
in Hours
1 Organizational Set up of Railway from Board to Workshop 02
2 Function of each department in short 02
3 Layout of Workshop with important facilities for each shop function 06
Role of Workshop, diff shops & its functions in brief, Attendance
4 12
monitoring: GA card punching/Digital/Bio metric
Reporting in Workshops- Targets, Planning, Statistics, Workshop
5 02
Portal, 100 days failure statistics
6 Role of Supervisors in Workshop & their responsibilities 03
7 Material Handling Methods & Equipment 06
8 Machinery & Plant Maintenance 12
9 Jigs, Fixtures & Gauges 12
10 Quality Management System (QMS) & TQM 12
ISO & EMS System in Workshop. Introduction to ISO 9001, ISO
11 14001 & ISO 50001, IMS 14001 & OHSAS 18001, Green-Co 06
Rating, ISO 3834, 5S, Lean six Sigma
12 Value Engineering, types of needs and demands 03
13 Production Planning and scheduling 06
14 Process inventory control 06
15 Industrial Safety Requirement & Procedure 06
16 Drawing usage, preparation, Modification & its record maintenance 03
Workshop Specific Labour laws, HOER, Workman Compensation
17 02
Act
Pollution and its Control Measures in Workshops, Solid Waste
18 03
Management, Effluent Treatment
19 Industry 4.0, CNC Machines 02
20 Revision 02
Total 108
Page 70 of 118
SUBJECT NAME WORKSHOP THEORY -02
SUBJECT CODE MWT-02
MODULE MSE-W, MJR-W
Duration
Sl. No Topic
in Hours
1 Work Measurement Techniques, Procedures & Analytical Methods 02
2 Work Sampling Methods 02
3 Work Sampling Techniques & Probability Theory 02
Incentive Scheme, Rate Fixing, Normalizing & AT fixing, Work
4 06
Order System & Procedure, Inspection Report sheets
Method Study Definition, Objectives & Procedures, On Cost
5 12
booking & methods to reduce on cost
6 Job Evaluation & Merit Rating 02
7 Job Costing 06
8 Inspection & Testing Procedure- DT & NDT Methods 03
9 CMT Lab functions 06
POH of different types of Wagons in Workshops, POH of different
10 types of Bogies of Wagons, Suspension System in wagon bogies, 04
Spring failure: causes and remedies
POH of Stainless Wagons in Workshops, Rehabilitation and
11 04
Conversion of Wagons
12 POH of ICF and LHB Coaches in Workshops 04
Details and Comparison of ICF and FIAT Bogies in Coaches, POH
13 of Bogies and their components, Suspension system in coach 04
bogies, Spring failure: causes and remedies
Coach Body Repair, Passenger Amenity Items, Bio Toilets & Bio-
14 06
vacuum Toilet fitment during POH
15 POH of TL & AC system of Coaches (ICF & LHB) 18
16 Corrosion Repair Practice in Coaches & Wagons & Underframe 12
Air Brake System of Coaches & Wagons, Twin pipe brake system
17 in wagons, Coupler: Balance draft Gears, POH Procedure & 06
Testing methods
18 POH of different types of Locomotives in Workshops 02
Wheel Shop, Flow and Maintenance Wheels, POH of Loco,
19 09
Coaches and Wagon Bearings in Shops.
NTXR Examination on Coaches & Wagons, NTXR reject able
20 03
defects, Local Passing.
Role of Stores Department in Workshops, Stock & Non-Stock
21 03
Items, Stocking, EAC & AAC of Material.
22 Stores drawl procedure 03
Page 71 of 118
Duration
Sl. No Topic
in Hours
Stocking Application procedure for new stock items,
23 06
Standardization, Rationalization, Specification, Purchase Cycle
Procurement of Non-Stock Items, Indenting, Requisitions, Technical
24 Suitability, Local Purchase, IREPS, iMMIS, GeM, long term 03
contracts
25 Manufacture activities in Workshops 03
26 Workshop Manufacturing Suspense 02
Condemnation of Coaches, Wagons and Locomotives, Excluded
27 02
Fittings
Condemnation of Ferrous & Non-Ferrous Scrap and its return to
28 03
stores
29 Machinery, Plant & Equipment used in Workshops 06
Painting schedule and types of paints used in C&W, Powder
30 06
Coating, Vinyl Wrapping, Grit Blasting
31 Warranty claims of coaching and wagon items 02
32 SPART/SPRMV & 140 T Crane maintenance practices 04
32 Workshop Visit 18
33 Revision 06
Total 180
Page 72 of 118
SUBJECT NAME WORKSHOP THEORY -03
SUBJECT CODE MWT-03
MODULE MJI-W
Duration
Sl. No Topic
in Hours
1 Organization setup of Railway from Board to workshop 02
2 Function of each department in short 02
3 Layout of workshop with important facilities for each shop functions 06
Role of workshop diff shops & its functions in brief, Attendance
4 08
monitoring: GA card punching/Digital/Bio metric
Reporting in Workshops- Targets, Planning, Statistics, Workshop
5 02
Portal, 100 days failure statistics
6 Role of supervisors in workshop & their responsibilities 02
7 Material handling methods & Equipment 06
8 Jigs, Fixture & Gauges 08
9 Quality managements item (QMS) & TQM 08
ISO & EMS systems in workshop, Introduction to ISO 9001, ISO
10 08
14001 & ISO 50001, IMS 14001 & OHSAS 18001
11 Value Engineering types of needs and demands, Industry 4.0 04
12 Production planning and scheduling 04
13 Process inventory control 06
14 Industrial safety requirement & procedure 06
Drawings usage, preparation, Modification & its Record
15 03
maintenance
Workshop Specific Labour laws, HOER, Workman Compensation
16 02
Act
Pollution and its Control Measures in Workshops, Solid Waste
17 03
Management, Effluent Treatment
18 Job costing 06
19 Standardization, Rationalization, Specification etc. 03
20 Inspection & Testing Procedure- DT & NDT Methods 03
21 CMT Lab functions. 03
POH of different types of Wagons in Workshops. POH of different
22 types of Bogies of Wagons, Suspension System in wagon bogies, 04
Spring failure: causes and remedies
POH of Stainless Wagons in Workshops, Rehabilitation and
23 04
Conversion of Wagons
24 POH of ICF and LHB Coaches in Workshops 04
Details and Comparison of ICF and FIAT Bogies in Coaches, POH
25 of Bogies and their components, Suspension system in coach 04
bogies, Spring failure: causes and remedies
Coach Body Repair. Passenger Amenity Items, Bio Toilets & Bio-
26 06
vacuum Toilet fitment during POH
Page 73 of 118
Duration
Sl. No Topic
in Hours
27 POH of TL & AC system of Coaches (ICF & LHB) 12
28 Corrosion Repair Practice in Coaches & Wagons & Underframe 06
Air Brake System of Coaches & Wagons, Twin pipe brake system
29 in wagons, Coupler: Balance draft Gears, POH Procedure & 04
Testing methods
30 POH of different types of Locomotives in Workshops 02
Wheel Shop, Flow and Maintenance of Wheels, POH of Loco,
31 08
Coaches and Wagon Bearings in Shops
NTXR Examination on Coaches & Wagons, NTXR reject able
32 03
defects, Local Passing
Role of Stores Department in Workshops, Stock & Non-Stock
33 03
Items, Stocking, EAC & AAC of Material
34 Stores drawl procedure 03
Stocking Application procedure for new stock items, Purchase
35 06
Cycle
Procurement of Non-Stock Items, Indenting, Requisitions, Technical
36 Suitability, Local Purchase, IREPS, iMMIS, GeM, long term 03
contracts
37 Manufacture activities in Workshops 03
38 Workshop Manufacturing Suspense 02
Condemnation of Coaches, Wagons and Locomotives, Excluded
39 02
Fittings
Condemnation of Ferrous & Non-Ferrous Scrap and its return to
40 03
stores
41 Machinery, Plant & Equipment used in Workshops 06
Painting schedule and types of paints used in C&W, Powder
42 06
Coating, Vinyl Wrapping, Grit Blasting
43 Warranty claims of coaching and wagon items 02
44 SPART/SPRMV & 140 T Crane maintenance practices 04
45 Industry 4.0, CNC Machines 04
46 Workshop Visit 14
47 Revision 03
Total 216
Page 74 of 118
SUBJECT NAME WORKSHOP THEORY -04
SUBJECT CODE MWT-04
MODULE MJI-W
Note: To be trained in any one of the following subjects depending on the trade
Carriage Shop
1 Layout, Organization structure, different sections of the shop
2 Salient features and constructional difference of coaches, repair practice at all stages
of POH of different
types of coaching stock. Modification to coaches for high speed running and
precaution taken there to.
3 Lifting of coaches- dismantling of bogies, wheels etc
4 Repair, Overhaul & testing of bogies frame, bogie components
5 Repair, Overhaul & testing of springs, draft gear, buffing gear
6 Repair, Overhaul & testing of Air brake components
7 Repair, Overhaul & Inspection of Wheel & Roller Bearings
8 Repair, Overhaul & testing of water tank
9 Body repairs
10 Carpentry work.
11 Lowering and Levelling of coaches
12 Corrosion repairs
13 Modifications done on coaching stock
14 Provision of safety fittings, provision of amenity fittings.
15 Painting of Coaches
16 NTXR examination
17 Train lighting,
18 DEMU/EMU Coach POH Workshop
19 Repair and maintenance of Bio-Toilets, Bio-Vacuum toilets
20 Shop wise staff strength, material requirement, M&P, T&P and targets
21 Attention of accident involved coaches & conversion of coaches
22 POH practices of buffers and couplers
23 Air conditioning and Train lighting
24 RSP works and modifications
25 IMS cell, Drawing, Safety cell, Planning, Budget, PCO, Rate fixing, Progress,
Inspection sections
Page 75 of 118
Wagon Shop
Wheel Shop
Page 76 of 118
Machine Shop
Page 77 of 118
SUBJECT NAME WORKSHOP THEORY -05
SUBJECT CODE MWT-05
MODULE MJP-W
DURATION 24 Days
Duration
Sl. No Topic
in Hours
1 Organization setup of Railway from Board to workshop 02
2 Function of each department in short 02
3 Layout of workshop with important facilities for each shop functions 02
4 Role of workshop diff shops & its functions in brief 02
5 Reporting in Workshops- Targets, Planning, Statistics, Workshop
02
Portal, 100 days failure statistics
6 Role of supervisors in workshop & their responsibilities 02
7 Material handling methods & Equipment 02
8 Jigs, Fixture & Gauges 02
9 Quality managements item (QMS) & TQM 03
10 ISO & EMS systems in workshop. Introduction to ISO 9001, ISO
06
14001 & ISO 50001, IMS 14001 & OHSAS 18001
11 Value Engineering types of needs and demands 03
12 Production planning and scheduling 06
13 Process inventory control 04
14 Industrial safety requirement & procedure 06
15 Drawings usage, preparation, Modification & its Record
03
maintenance
16 Workshop Specific Labour laws, HOER, Workman Compensation
02
Act
17 Pollution and its Control Measures in Workshops, Solid Waste
03
Management, Effluent Treatment
18 Job costing 05
19 Standardization, Rationalization, Specification etc. 02
20 Inspection & Testing Procedure- DT & NDT Methods 02
21 CMT Lab functions 02
22 POH of different types of Wagons in Workshops. POH of Different
types of Bogies of Wagons, Suspension System in wagon bogies, 02
Spring failure: causes and remedies
Page 78 of 118
Duration
Sl. No Topic
in Hours
23 POH of Stainless Wagons in Workshops, Rehabilitation and
02
Conversion of Wagons
24 POH of ICF and LHB Coaches in Workshops 04
25 Details and Comparison of ICF and FIAT Bogies in Coaches, POH
of Bogies and their components, Suspension system in coach 03
bogies, Spring failure: causes and remedies
26 Coach Body Repair, Passenger Amenity Items. Bio Toilets & Bio-
04
vacuum Toilet fitment during POH
27 POH of TL & AC system of Coaches (ICF & LHB) 04
28 Corrosion Repair Practice in Coaches & Wagons & Underframe 04
29 Air Brake System of Coaches & Wagons, Twin pipe brake system
in wagons, Coupler: Balance draft Gears, POH Procedure & 04
Testing methods
30 POH of different types of Locomotives in Workshops 02
31 Wheel Shop, Flow and Maintenance Wheels, POH Loco, Coaches
06
and Wagon Bearings in Shops
32 NTXR Examination on Coaches & Wagons, NTXR reject able
03
defects, Local Passing
33 Role of Stores Department in Workshops, Stock & Non-Stock
03
Items. Stocking, EAC & AAC of Material
34 Stores drawl procedure 03
35 Stocking Application procedure for new stock items, Purchase
06
Cycle
36 Procurement of Non-Stock Items; Indenting, Requisitions, Technical
02
Suitability, Local Purchase, IREPS
37 Manufacture activities in Workshops 03
38 Workshop Manufacturing Suspense 02
39 Condemnation of Coaches, Wagons and Locomotives, Excluded
02
Fittings
40 Condemnation of Ferrous & Non-Ferrous Scrap and its return to
02
stores
41 Machinery, Plant & Equipment used in Workshops 03
42 Painting schedule and types of paints used in C&W, Powder
03
Coating, Vinyl Wrapping, Grit Blasting
43 SPART/SPRMV & 140 T Crane maintenance practices 04
44 Industry 4.0, CNC machines 02
45 Workshop Visit 06
46 Revision 02
Total 144
Page 79 of 118
INDEX- GUIDELINES FOR PRACTICAL TRAINING
Page 80 of 118
GENERAL
• The trainees will report to Cl/BTC and meet Principal/BTC on first day in
Workshop and PU. In other units they have to meet the nominated Training In-
charge.
• Nominated Instructor of BTC or supervisor should take around the premises on
first day and will explain important areas of each sub unit.
• The detailed schedule of training will be given to the trainee with an awareness of
organization, activities, products and technologies of the unit.
• Diaries should be meticulously maintained daily, based on observations made
and periodically systematized in form of summaries/gist in organized manner.
This will greatly assist in retention of knowledge gained, apart from being a
mandatory requirement of training.
During each field training the trainees are required to proceed from broad
aspects to minor details as given below:
3. The unit wise guidelines given below can be modified by unit in which training is
imparted, to allow inclusion of other important areas considered relevant and
exclusion of areas that may be redundant.
Page 81 of 118
I. TRAINING GUIDELINES FOR ICF
1. DESIGN
a) Study of 1000 T and 800 T Hyd. Presses with special emphasis on CNC
and Plasma Turret Press.
b) Shearing machine with special emphasis on CNC shearing centre
c) Butt seam welding machines.
d) Spot welding machines.
e) Profile bending machines.
f) Notching machines.
g) Submerged arc welding machines.
i. Side wall assembly.
ii. End wall assembly.
iii. Hot phosphating and cold phosphating procedures.
3. Study of following
Page 82 of 118
4. Study of following:
5. SPRING MANUFACTURING
7. COMPONENT SHOP
8. MILLWRIGHT
9. TOOL ROOM
Page 83 of 118
10. INSPECTION
11. FURNISHING
Study of stage wise assembly of interior furnishing.
Preparation of laying of vermiculate, decolite mixing and coach flooring, roofing
and roof wiring.
Interior paneling for sides and roof.
Plumbing and lavatory fittings.
Interior wiring, fitting of seats and berths, assembly of vestibule arrangements,
fitting of windows etc.
Study of
a) Wood working techniques
b) Seasoning of timber.
c) Impregnation treatment.
d) Various paneling materials.
e) Manufacture of items with F.R.P
12. Study of
a) Window assy.
b) Vestibule assy.
c) Manufacture of aluminum water tank.
Page 84 of 118
13. General study of trimming process.
14. Study of Air Brake arrangement for EMU, Metro & Rajdhani coaches & Train-
Sets
15. Study of Electroplating and Anodizing process.
16. Planning Department
Study of
a) Work order system.
b) Planning for production
c) Preparation of design and drawings for new builds.
d) Process planning
e) Maintenance of computer master files.
f) Release of production documents
g) Accountal of shop manufactured items.
Study of functioning of
a) Centralized P.C.D
b) Shop P.C.D
Page 85 of 118
II. GUIDELINES FOR RCF/KAPURTHALA
While visiting RCF/ Kapurthala, following items may be specifically looked into:
1. The production flow- Plant lay out, various stages of manufacturing of the
Coaches
Page 86 of 118
6. Energy conservation
- Street lighting with timers
- Solar water heaters
Page 87 of 118
III. GUIDELINES FOR RWF, BANGALORE
1. AXLE SHOP
3. CMT
Page 88 of 118
IV. GUIDELINES FOR DLW TRAINING
Page 89 of 118
Engine Test Shop:Load Box Test
Traction assembly:
Power pack with Traction Alternator and control equipment testing, Pneumatic
testing
Pre-Departure Inspection:
• Understanding of various Inspection Checklist
• Vendor development system
• Marketing wing of DLW- Organization, Working etc, DG Sets
Page 90 of 118
V. GUIDELINES FOR TRAINING AT DMW, PATIALA
Page 91 of 118
VI. GUIDELINES FOR DIESEL SHED TRAINING
• Organization chart
• Shed layout
• Power plan, Outage and other Shed performance characteristics.
• Study schedule forms for minor and medium schedules (Mech. & Elec.)
• Study the history cards of locomotives and method or forecasting and
planning their schedules.
• Yearly schedule- Details of activities, their PERT chart and execution.
• Attend one shift each with Shift in Charge (M) & Shift in Charge (E) and
observe their working.
• Observe load box test of Loco after major schedule and study the records.
Plot control chart for some important characteristics.
• Study and observe the complete failure investigation of a Locomotive.
• Study the availability of staff, Infrastructure and M&P items in the shed and
their adequacy.
• Study the system of receipt & issue of fuel oil and the details of various
monthly statements sent to HQ
• Study the calculation of S.F.C (Loco wise and service wise) and shed
consumption.
• Study schedule forms for various minor & medium schedules (Mech. & Elec.)
Attend various maintenance section (Mech. & Elec.). Study M.ls for the
section and observe details of various checks and measurements.
• Study the system of Drawl of items from stores and their accountal.
• Study the system of procurement of various items (Imprest, Stock &
Nonstock)
• Foot plate a Locomotive out from shed and observe the working of crew.
• Facilities- infrastructure, staff, training and M&P items- available & required
• Technical Cell - History cards. Failure investigation, Schedule planning.
Performance indices, Technical instructions.
• Spares Cell - Systems of procurement of (a) imprest items, (b) Stock items &
(c) Non stock items, System of drawal of items from Stores and their
accountal.
• Fuel and statistical cell - System of receipt and issue of fuel oil, Calculation of
S.F.C (Loco wise & Service wise) and Shed consumption, details of monthly
statements.
Page 92 of 118
VII. GUIDELINES FOR DIESEL POH WORKSHOP TRAINING
Page 93 of 118
VIII. GUIDELINES FOR CARRIAGE POH SHOP
Page 94 of 118
IX. GUIDELINE FOR WAGON POH
GENERAL
WAGON
REPORT
1. Make a report showing the actual POH cycle of any air braked wagon POHed at
the workshop during your visit.
2. Make a report describing in detail on Re-axling/Re-discing of wheel sets in the
workshop you visited.
3. Prepare a duplicate inspection sheet of any wagon and make network for POH
cycle.
4. Categorization of wagons in A, B & C category.
DO IT YOURSELF
Page 95 of 118
X. GUIDELINES ON COACHING DEPOT/DIVISION WORKING
Understand
i) i)Organization structure of Mechanical department of the division
ii) Spread of division indicating C&W facility & important features of the particular
division.
iii) Contents of Sr. DME’s stock position
iv) Analysis of loss of punctuality of Mail and Express trains.
v) Pit occupation chart
vi) Layout of coaching maintenance yard.
vii) Layout of sick line.
viii) Procedure for sending coaches for POH/IOH.
x) Examination of date and sick marking of coaches.
x) Maintenance of Distributor valve.
Study the system for maintenance of coach history cards and forecast of
xi)
maintenance schedules to be done.
xii) Maintenance of Brake gear.
xiii) Testing of air brake system.
xiv) Rake links.
xv) Distribution of staff in sick line.
xvi) Function of batch in maintenance yard.
xvii) Replacement of primary spring and secondary spring
xviii) Maintenance and upkeep of Bio-toilets
xix) Foot plate inspection.
xx) Plants & equipment in maintenance yard and sick line.
xxi) Schedule maintenance of coaches.
xxii) Cleaning agents used in washing line.
xxiii) Provision in ART.
xxiv) Analysis of en route detachments.
xxv) Derailment enquiry.
xxvi) Corrosion prone areas of coaches.
xxvii) Marshalling in a rake
xxviii) Study the system for maintenance of coach history cards and forecast of
maintenance schedules to be done.
xxix) Study of CMM portal, BPC generation and data analysis through MIS.
xxx) Effluent Testing Procedure and parameters.
Monitoring of Works contract related to Mechanized Cleaning of Coaches, CTS,
xxxi) OBHS, AMOC of Bio Toilet, Pest & Rodent Control etc. GCC and Special
Terms & Conditions of contract.
xxxii) Maintenance of AC & Non-AC type LHB coaches
xxxiii) Maintenance of Critical components of LHB coaches, WSP, Disc Brake, BDG,
Air Spring, etc
xxxiv) Overview of Special type Rolling Stock: - Deen Dayalu Coaches, Utkrisht
Coaches, Humsafar Coaches, Anubhuti Coaches and Train18 trainset, etc.
xxxv) Introduction to Machinery and Plants used in Coaching Maintenance Depot: -
Screw Compressors, RTR, SCTR, Fork Lift, Lister Truck, EOT Crane, Gantry
Hoist, Diesel Hydraulic Road Crane, ACPW, WILD, Hot Axle Detector System,
Enroute Quick Coach Watering System, Water Recycling Plant, ETP etc
xxxvi) Mechanized Laundry-operation and maintenance.
Page 96 of 118
xxxvii) Linen Management.
xxxviii) Online Complain Management System- Rail Madad portal and Coach-mitra.
xxxix) Project work: - Framing of Proposal, Feasibility Report, ROR, Tendering
xxxx) EnHM- Objective, organization structure and functioning.
Primary, Secondary & Turn Around Maintenance schedule as per RPC-IV
Prepare Report
i) Summarize loss of punctuality of mail & express train for the last 6 months.
Suggest methods to reduce loss of punctuality.
ii) Prepare report or overdue POH coaches of or coaching depot. Suggest methods
to reduce overdue coaches in trains services.
iii) Prepare sick making of coaches for the last 6 months. Make Parches Paretos
analysis and suggest methods to reduce coach ineffectiveness.
iv) Prepare report of sick making of coaches within 100 days of POH. Suggest to
improve such incidents.
v) Prepare report on major plants and equipment of the coaching depot and
highlight maintenance practice adopted and suggest any improvement on
present method of maintenance practice.
vi) Prepare report on critical items of the coaching depot. Suggest methods to
Page 97 of 118
improve problem of “Stock out”.
vii) Prepare a chart for the occupation of washing and pit lines. Attach a complete
report of activities undertaken in your coaching sick line under different headings
viii) Write a failure report and your own analysis for two coaching stock failures
resulting in detention and/ or detachments en route, (attach sheets).
Page 98 of 118
XI. GUIDELINES OF ROH DEPOT
DO IT YOURSELF
i) Replace MV user.
ii) Isolate DV.
iii) Perform Take up/Pay out test.
iv) Connect Air Hose Pipe.
v) Release Brake Binding
Page 99 of 118
XII. GUIDELINES FOR TRAINING IN GOODS YARD
1. Examine one originating, one terminating and one by-pass goods train in each of
the three shifts, from the stage of receipt of a train examination memo from the yard
master till the issue of BPC or release memo. Write your observations about time
taken, defects noticed, inadequacy of tools, light, C&W duplicates and observations
due to unclean yards with date, yard, shift, name of TXR, train no., event times etc.
(attach sheets).
2. Perform a complete brake power check on a train load in yard. Note the sticky or
defective cylinders, overdue POH cylinders, leaky cylinders, repairs attended at site
and the percentage of operative cylinders (Attach sheets).
3. Observe the functioning of NTXR flying squad if provided on your division and
follow up the report of NTXR for its implementation.
4. Deal with a clearance of ODC consignment fully and write a two-page report. How it
is important for a heavy consignment to be carefully loaded and why? How should
shifting of a heavy consignment during run be prevented? (Attach sheets).
5. What are the pros and cons for a train examination being conducted on an
originating train or a terminating train? What system is being followed on your
division? How is it related to the yard operations?
6. What are the average figures of POH booking from your yards and how the figure is
to be kept in check? Make a critical study over a 15-day period to access the
wagons awaiting heavy repairs on your division to indicate whether it is showing an
increasing trend. Do you consider the existing repair facilities on your division
adequate for the load arising? Are there an original foundation in your work load
arising (attach sheet)?
7. Critically study detachments en-route due to wagon defects. Analyze them cause-
wise and write a report to suggest remedial action. Are there some seasonal
variations?
8. What is the procedure adopted to clear way side detached wagons? What is the
average detention at way side stations? What is the incidence of repeated
detachment of such wagons? (Attach sheets)
9. Study the ineffective wagons lying on your division and categorize them according
to the no of days they have been lying ineffective. Propose a plan action to deal
with the problem in two-page report with facts and figures (Attach sheets).
10. What are the rules regarding booking of heavy repair NPOH wagons to shops?
Examine the repair facilities provided on your division to deal with such heavy
repairs arising if this work load is considered important.
11. Spend a full day at a major siding say FCI or an OIL siding or a tippler siding.
Examine the records of placement and removal of loads, loading/unloading
facilities, system of handing over and taking over for working out the damages and
efficiencies and any other point of managerial interest (Attached sheets)
12. Study LPG loading/unloading facilities, if any provided on your division including the
safety aspects.
13. Study the special precautions for loading/unloading or passing of POL rakes
through your division including a personal examination of all the fittings of a petrol
tank wagon on the diaphragm and the bottom discharge point. Examine the
calibration, dipstick measurements and commercial aspects of POL traffic. Mention
important observations (Attach sheets).
EXAMINATION
Marks*: Showing the approximate weightage of subject topic in the examination paper.
Marks*: Showing the approximate weightage of subject topic in the examination paper.
Marks*: Showing the approximate weightage of subject topic in the examination paper.
Marks*: Showing the approximate weightage of subject topic in the examination paper.
QUESTION BANK
A) C&W