WEST CENTRAL RAILWAY

REGIONAL RAILWAY WELDING INSTITUTE (RRWI)

(RECOGNISED BY RAILWAY BOARD AS WELDING TRAINING CENTRE) (WTC)

Located at Coach Rehabilitation Workshop, Bhopal (An ISO 9001:2000, ISO 14001:1996 & OHSAS 18000 Certified)

RRWI MAP

1. RRWI

Location of the Training Institution

RRWI MAP West

South North

East

Coach factory road

Main gate

Colony gate

TTC – Technical Trainning Center

BPS – Bal Bharti Public School

Bhopal Rly. Station PF No.- 1 side

Temple

Divisional Railway hospital

Administrative building Coach rehabilitation Workshop/Bhopal

Hostel TTC

BPS Regional Railway Welding Institute

CRWS Colony

RRWI PERFORMANCE ZONE & MODULE WISE YEAR - 2006 – March - 2015

Module Railway wise trainees Other Railway Total

Trainee WCR CR NCR WR NWR NER+SECR+NFR

+ER+ECR+ECoR

I 493 78 207 59 51 53 941

II 626 364 160 156 75 99 1480

III 75 13 36 08 02 12 146

IV & V 28 06 13 03 03 05 58

MRT - 10 00 00 07 02 18 00 27

Others BHEL - 28 SKILL - 62 Sup. - 42 Helper - 04 Total - 136 2788

ZONES AND YEAR WISE YEAR - 2006 – Sep. 2015

Year Railway wise trainees Other

Railway Total WCR CR NCR WR NWR

2006 - 2015 1222 461 423 228 152 302 2788

2015 - 2016 37 51 17 61 11 18 195

1259 512 440 289 163 320 2983 “C” GRADE IMPROVEMENT OF WELDER

OF KOTA WORKSHOP 34 34

Skill development course for youth 29 29

Grand Total 3046

Module & YEAR WISE YEAR - 2006 – Sep. 2015

Module 06-07 07-08 08-09 09-10 10-11 11-12 12-13 13-14 14-15 15-16 Total I 0 76 90 233 64 114 70 140 154 99 1040 II 17 146 163 145 168 187 268 191 195 96 1576 III 0 0 31 29 16 18 16 6 30 0 146

IV & V 0 0 0 7 5 13 16 11 6 0 58 MRT -

10 0 0 0 0 0 0 0 0 27 0 27

Total 17 222 284 414 253 332 370 348 412 195 2847 Others 136

“C” GRADE IMPROVEMENT OF WELDER OF KOTA WORKSHOP 34 Skill development course for youth (For non Railway) 29

GRAND TOTAL 3046

PREFACE

Welding Technology has emerged as an important and critical process of manufacturing and repair in Railway Workshop. The biggest challenge to Railway Workshop is to sustain quality of welding in critical area of Rolling Stock specially of under frame and under slung equipment. The quality of welding is function of Welders skill and welding equipments.

Indian Railway is deploying approximately 20,000 Welders and majority of them are promoted from Khalasies i.e. Group ‘D’ staff. Thus emphasizing the need of proper training to Railway staff who are choosing Welding Trade as their profession.

SRSF Committee (Khanna Committee Part-I) has also recommended at Para 5.10 for competency-based training for work centers such as TXR depots, ROH depots & WORKSHOP etc.

Railway Board vide their letter No.2000/M(M&P)1063/II dated 13.04.01 have appointed a SAG level committee to assess feasibility & desirability of setting up of Training Centers to improve welding quality among Railway Welders. This committee has studied in detail the requirement of welding Training to Railway staff and has submitted exhaustive report for setting up of Regional railway Welding Institute (RRWI) at following 4 locations :-

1. RCF Kapurthala. 2. DLW Varansi 3. ICF/Chennai. 4. CRWS/BPL 5. Khadagpur

These Training Institutes cater the training requirement of All Indian Railway Welders. This Training Institute provides training for beginners, Refreshers, Pre-promotional and special training as and when required. Keeping in view, the different training need of Staff, five modules of training have been prepared.

Unlike POH workshops, Coach Repair Workshop, Bhopal is a unique Workshop for the rehabilitation of coaches of INDIAN RAILWAY. Its activities are focused towards corrosion repair & total rehabilitation of body, under frame members. This involves modern gas/plasma cutting & welding of structural member followed by refurnishing of full coach once in the life.

The workshop has ISO-9001: 2000 for quality & its management system, ISO-14001 for its environment management system & ISO-18001 for occupational health & safety.

We are using all modern techniques in the repair of coaches like CO2 welding, TIG welding, plasma cutting, grit blasting of coaches & its components etc. We also have a MOU with BHEL, Bhopal for demonstration of latest welding & cutting technology to our trainee welders.

The center has number of qualified trainers, workshop, modern teaching-aid equipments, Class rooms, auditorium, and welding laboratory with ‘X’--rays facility, and model room for accomplishing its aim and objectives. The center is doing the job of training since last eight years and with the co-operation and ideas / suggestions of its users will continue on the path of progress and prosperity of INDIAN RAILWAY.

MISSION STATEMENT

“TO DEVELOP THE POSITIVE ATTITUDE,

KNOWLEDGE, SKILL & WORKMANSHIP OF

RAILKWAY WELDERS WHICH IMPROVES THE

QUALITY & GOOD WILL OF ORGANIZATIONAND

ALSO MOTIVATE THEM FOR INCREASING THE

RODUCTIVITY & IMPROVEMENTS IN THE

PERFORMANCE OF THE INDIAN RAILWAYS.”

INTRODUCTION REGIONAL RAILWAY WELDING INSTITUE, Bhopal (RRWI)

(Known as Welding training Institute (WTC) Recognized by Railway Board)

REGIONAL RAILWAY WELDING INSTITUE, Bhopal (RRWI) of west central railway is situated in the city of lakes of M.P It is located about a distance of 03 KMs from the Bhopal Railway station & attached with Coach Rehabilitation Workshop.

RRWI was established in the year Jan.2007, to cater the training need of the welding supervisors & welders of the mechanical department.

Special courses as well need base training programs to meet the training need of the Indian Railway welders are also conducted at RRWI/Bhopal. Training centre has over the year developed excellent relationship with the division and workshops of Indian Railway in its jurisdiction.

METHODOLOGY OF TEACHING Lectures, group discussions, audio-visuals, demonstrations & practical

facility of welding in all position by SMAW,GMAW, Plasma cutting, TIG welding and display of charts & board. All presentations on power point and display charts are bilanguage i.e. Hindi & English. Welders visit to BHEl, Bhopal & Industrial area Govinpura, to see latest welding & cutting processes in fabrication industries. Welders job evaluations being done in weld Laboratory. The feedbacks of trainees are being taken from their shop incharge/SSE and suggestion collected from trainees & customers to increase productivity & quality in welding.

RRWI WELDING TRAINING MODULES

Module Description of Modules Duration of the Course in weeks

Theory Hrs.

Practical Hrs. Remarks

I

Basic welding training for beginners (Promotees from khalasis and skilled grade III direct recruits) This will give them enough knowledge and confidence about welding for their day-to-day work.

04 45 135

II On the job continuous improvement training (Refresher course) 03 45 90

III Need based training on specific topics like Weld Distortion, Metallurgy and weld joints design.

02 45 45

IV Training for welding supervisor, welding inspectors and C&M staff in service.

02 45 45

V Training for newly recruited welding supervisor (Direct recruits). 02 45 45

VI Requirements for training of Training Officers, welding instructors in welding institutions.

This Modules conduct by nodal agency DLW Varanasi

VII Training for Junior and Senior scale officers of mechanical branch including CMTS and ACMT’s

RRWI WELDING TRAINING MODULES MODULE-I

BASIC WELDING TRAINING FOR BEGINNERS

This is basically for those staff that gets into the welding trade on promotion from Group-D to Gr.III and Skilled Gr.III direct recruited. This will give them enough knowledge and confidence about welding for their day-to-day work.

Duration of the Course : 4 Weeks Theory : 45 hrs. Practical : 135 hrs.

MODULE-II ON THE JOB CONTINUOUS IMPROVEMENT TRAINING FOR REFRESHER COURSE

This module has been planned for Welders with one or two year experience in repair shop. This will refresh their knowledge and up-grade their skill. It shall be mandatory in nature for promotion from Group-III to Group-II and Group-II to Group-I.

Duration of course : 3 Weeks Theory : 45 hrs. Practical : 90 hrs.

MODULE-III NEED BASED TRAINING ON SPECIFIC TOPICS LIKE WELD DISTORTION, WELD

JOINT DESIGN AND THEIR METALLURGY

Duration of course : 2 Weeks Theory : 45 hrs. Practical : 45 hrs.

MODULE-IV TRAINING FOR WELDING SUPERVISORS, WELDING INSPECTORS

AND C&M STAFF

This module is designed for Welding Supervisors; Inspectors & C&M staff to up-grade their knowledge.

Duration of course : 2 Weeks Theory : 45 hrs. Practical : 45 hrs.

MODULE-V TRAINING FOR NEWLY RECRUITED SUPERVISORS (JE-II & SE)

All trainee supervisors in Welding Trade will need to undergo this module. All direct recruits supervisors, JEs shall under go in Module-I & II during 1st year and Module-IV during 2nd year. Duration of course : 2 Weeks Theory : 45 hrs. Practical : 45 hrs.

MAJOR AREAS COVERED AT RRWI/BHOPAL

p Manual metal arc welding

p Gas metal arc welding (MIG,MAG,FCAW & TIG)

p Welding joints ,Position Symbols & terminology

p Welding defects & its remedies

p Inspection & testing of weldments

p Metal cutting processes

p Weld quality & distortion control

p Modern welding & SS welding

p Practices on skill up gradation of welders

p Knowledge of weld consumables

RRWI is equipped with the following modern training audio-visual aids. All presentation developed by teaching staff on power point are bi-language i.e. Hindi & English which includes text & diagrams.

LCD PROJECTOR DIGITAL CAMERA 21” MONITOR

OVER HEAD

PROJECTORS

SPIRAL BINDING MACHINE

VCD PLAYER

WHITE BOARDS DIGITAL PHOTOCOPIER PERSONAL

COMPUTERS

COMBI BOARDS TRANSPARENCIES (DEVELOPED BY

TEACHING STAFF OF RAINING CENTRE).

DOT MATRIX PRINTER

COLOUR INK JET PRINTER

TRAINING AIDS

WELDING TRAINING INFRASTRUCTURE

TRAINING FACILITIES

• MMAW Welding plants transformers – 04 Nos

• MMAW Welding plants rectifiers – 05 Nos

• MIG/MAG Welding plants – 05 Nos

• TIG welding plant – 01 No.s

• Inverter base Pulse MIG welding – 01 No.s

• Plasma Cutting Machine – 01 No.s

TESTING FACILITIES

• Impact testing M/C

• Universal testing machine

• Portable radiographic x ray unit

ASSESSMENT FACILITIES

• Microscopes

• Magnetic particle inspection

• Dye penetration Kit

• Tong tester

• Weld gauges

WELDER GRADING SYSTEM

• Category ‘A’ -- 80% and above

-- Eligible for critical & safety welding items

• Category ‘B’ -- 65% to 79%

-- Eligible for critical & safety welding items

• Category ‘C’ -- 50% to 64%

-- NOT Eligible for critical & safety welding items

only suitable for rough & tack welding

• Category ‘D’ -- below 50% (Fail)

-- NOT Eligible for welding and rebook in training

Within three month

MODEL ROOM Model room is equipped with the various boards, charts & welding and

cutting items for demonstration of trainees.

SAFE WELDER

MODEL ROOM SET UP

REGIONAL RAILWAY WELDING INSTITUTE

LIBRARY

A Library which having a collection of 1100 books, covering a wide range of Engineering, Management, Railway Engineering subject, & a Hindi section with 750 Books on literature are available for the benefit for the trainees. Varies technical pamphlets and manuals are also available.

BILINGUAL DISPLAY BOARD IN WORK SHOP

BILANGUAL DISPLAY BOARD

MODEL OF CORRECT METHOD OF EARTHING IN WORKSHOP

CORRECT METHOD OF EARTHING

äMESSING FACILITY

Managed by contractor on contract basis

��º¾

Hostel is provided with TV and reading room.

Newspaper in Hindi & English and magazines are also available.

SPORT FACILITY:

Excellent facilities for outdoors and indoors are also available.

S.No. OUTDOOR GAMES INDOOR GAMES

1. VOLLEY BALL TABLE TENNIS

2. CRICKET CAROM

3. BADMINTON CHESS

ENTERTAINMENTS AVAILABLE

hMEDICAL ASSISTANCE AVAILABLE

Medical assistance is available 24 hours as division hospital is situated at 600 meters distance from the training Centre.

Emergency Tel. No. 7520 (for Doctor on duty)

DESIGN.

RLY. OFFICE

P&T OFFICE MOBILE

CWM 7400 0755 - 2742785 9752416450

Dy.CME 7404 0755 - 2746062 9752416452

(Trg. Officer/ CMT 7477 0755 - 2740396 9752416155

CI/RRWI 7473 0755 - 2746068 9752416182

Hostel 7928 0755 - 2476681 ---

Fax No. 0755 - 2743863, 0755 - 2747290

WCR Web site www.wcr.indianrailways.gov.in

E – Mail crwsbpl@gmail.com,

crwsbpl@rediffmail.com prageshnimbalkar@gmail.com

maliksaketbpl@yahoo.com

COMMUNICATION

REGIONAL RAILWAY WELDING INSTITUTE ( Recognised by Railway Board as Welding Training Centre) COACH REHABILITATION WORKSHOP, BHOPAL

TRAINING CALENDAR WELDING COURSES FOR WCR, CR, NCR, WR & NWR – YEAR – 2015 (Welder gradation certificate course approved by Railway Board)

S.

No. Month

MODULE – I MODULE – II MODULE – III MODULE– IV&V MRT –10 (AS PER RLY. BOARD TRG. MANUAL)

Training For New welders

Training for Experienced welder (Refresher Course)

Need based training for welders after completion of Module I /II

Training for Mechanical supervisors in field of welding

Training for new recruit engineer App.JE/SSE of Mechanical depot

STC/AJMER & JHANSI Will book directly

Starting day:- First Monday of Every month of all Modules of welding Starting day:- Fourth Monday of Every month

Duration - 04 Weeks Duration - 03 Weeks Duration - 02 Weeks Duration - 02 Weeks Duration - 01 Weeks

COURSE FROM TO COURSE FROM TO

Welders can be booked for special training in MIG/MAG/Co2 ,

Plasma cutting and Stainless steel welding

Module – III in November month only

Experienced, newly recruited & promoted supervisor may be

booked

Module – IV & V in November month only

FROM TO

01 Jan. – 15 82 05/01/15 31/01/15 87 05/01/15 24/01/15 24/01/15 31/01/15

02 Feb. – 15 83 02/02/15 28/02/15 88 02/02/15 21/02/15 Course No. – 03 in month of January

03 March-15 84 02/03/15 28/03/15 89 02/03/15 21/03/15

04 April – 15 85 06/04/15 02/05/15 90 06/04/15 25/04/15 27/04/15 02/05/2015

05 May – 15 86 04/05/15 30/05/15 91 04/05/15 23/05/15 Course No. – 04 in month of May

06 June – 15 87 01/06/15 27/06/15 92 01/06/15 20/06/15

07 July – 15 88 06/07/15 01/08/15 93 06/07/15 25/07/15 27/07/15 01/08/15

08 Aug. – 15 89 03/08/15 29/08/15 94 03/08/15 22/08/15 Course No. – 05 in month of July - August

09 Sep. – 15 90 07/09/15 03/10/15 95 07/09/15 26/09/15

10 Oct. – 15 91 05/10/15 31/10/15 96 05/10/15 24/10/15 COURSE No. – 23 From 02/11/15

TO - 14/11/2015

COURSE No. – 08 From - 02/11/15 TO - 14/11/2015

26/10/15 31/10/15

11 Dec. – 15 92 07/12/15 02/01/16 97 07/12/15 26/12/15 Course No. – 06 in month of October

12 Nov. – 15 MODULE – III , IV & V

For more details please contact

CI/RRWI Rly. – 016 – 7473 M – 09752416182

Training Officer-CMT M – 09752416155 Rly. – 016 – 7477

P &T - 0755 - 2740396

Dy.CME(MR) M – 09752416452 Rly. – 016 – 7404

P &T - 0755 – 2746062

OFFICE FAX 0755 – 2743863 0755 – 2747290

WCR Web site -- www.wcr.indianrailways.gov.in E -Mail-crwsbpl@gmail.com & maliksaketbpl@yahoo.com

CRWS Facebook A/C – To View RRWI Gallery

Ø Nomination of welders can be done for entire year well in advance for full utilization of courses. Welders will report to institute along with dangri & safety shoes and may not avail leave during training period. As per Railway Board guidelines, welders of Module –I & II to be evaluated on the basis of theory and practical test and awarded Grade A, B, C, & D

Grade “A” for 80% and above marks -- ‘A’ Grade welders are eligible to weld all critical welding joints

Grade “B” for 65% to 79% marks -- ‘B’ Grade welders are eligible to weld all critical welding joints Grade “C” for 50% to 64% marks -- ‘C’ Grade welders can be authorized in tack welding and gas cutting work only)

Grade “D” for Below 50% -- ‘D’ Grade welders not allowed for welding and should undergo training again till found suitable for welding job.

Ø New welder after getting training in Module – I must continue practice to develop their proficiency in welding jobs. Ø The hostel accommodation will be provided to trainees during training period, but mess charges will be borne by individuals. Ø Special courses, if required can be organised with prior approval of CRWS/WCR/Bhopal. Ø Welders may be rebooked in refresher course only after completion of 05 years and those due for retirement within 01 year and suffering from chronic disease may not be deputed. Ø

Approved by CWM/CRWS/ BPL

INSTRUCTIONS FOR THE GUIDANCE OF THE TRAINEES ATTENDING COURSES AT RRWI/BPL

1. The working hours of this training centre are from 8.30 hrs. to 12.15 hrs. and

13.00 hrs. to 16.30 hrs. Except on Sunday & holidays.

2. No leave will be granted to trainees during the period of training except in

emergency cases.

3. Hostel accommodation will be provided to all trainees attending training at

RRWI/BPL on first cum first served basis to the extent possible.

4. This training centre will provide Pillow, Blanket, Bed sheet and Mosquito

net/Jet machine to trainees during their stay in hostel.

5. The mess facility on contract basis for trainees available. Trainee shall

deposit an amount of Rs. 1500/1000 on joining, which will be adjusted against

dues latter on.

6. No trainees will be permitted to leave the hostel premises without permission,

except in emergency cases.

7. All trainees have to maintain upmost discipline in the training centre &

hostel. Smoking, tobacco-chewing, pan-spitting, Drinking is sticky prohibited

in RRWI & Hostel, violation of rule is liable to sent back with the

termination of training.

8. Visitors are not allowed to stay in the hostel during night hours without

permission from Training officer/ Chief Instructor except in emergency

cases.

9. Trainees attending the course should be well dressed with safety shoes and

welders should bring their Dangri /Boiler suit for practical training.

10. All the trainees required to clear their dues from library, mess & deposited

their helmet to this office, before reliving.

----------X------------