19AU029 RAILWAY REPORT.pdf Supervised Training

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PUNJAB TIANJIN UNIVERSITYOF
TECHNOLOGY, LAHORE
Pakistan Railway Training Workshop Mughalpura Lahore
Industrial Training Report
Name Shahzaib Akbar
Reg No. 19AU029
Department Automotive Engineering Technology
Industrial training course Supervised Industrial Training
Training Duration Sixteen Week
Training Organization Pakistan Railway Mughalpura, Lahore

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Abstract:
I have learned a lot of things during my 4 months of industrial training in Pakistan
Railways workshops. There are several sections and sub-sections in work shops where I
have gone through and gain knowledge about industrial practices and technologies.
During my training in Pakistan railways, I learned multiple skills including time
management and load management at the worksite as Ill. In all workshops of the railways,
there are different environmental conditions happen. I learned that how could I work in
multiple environmental conditions to satisfy my senior staff and to manage workload
regarding maintenance and repairing of high profile equipment.
I understand the structure of the organization. The nature of work in every department
of the organization and the electrical equipment installed in every site of the workshops.
There are many machines installed in all workshops such as fabrication machines,
processing machines, testing machines, and other general-purpose machines. As I was in
the maintenance team at all workshops, I learned the maintenance process and major
factors that affect a perfect maintenance process. I worked on the general electrical
system, hydraulic machines, AC machines, and also some DC machines with my
maintenance team.
I faced some problems and found some solutions as Ill. I assume some conditions to
test the process and find some recommendations for further innovation and improvement
of the work at the multiple sites of railway workshops.
The report is written as per the requirement of our internship, automotive engineering
technology in Llocomotive loco and carriage and wagon shop for duration of four weeks
.The report includes the complete orientation of the locomotive works that located in
Mughalpura Lahore. This report is based on the working experience in different
workshops of locomotives, providing necessary knowledge about railway workshop
system.

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Acknowledgment
I’ve completed my 4 months of industrial training successfully in Pakistan Railways
workshops located in Lahore. I worked in a very co-operative environment. All foreman
and high authority staff of Pakistan Railways come us in their section and give us free
hand to learn and grow with their teams. I’m very thankful to all cooperative and kind
persons who have helped me to work with them in a friendly environment. In the carriage
and wagon shop, special thanks to Mr. Waqar who guided Ill and put me on the right
path, and recommend me, good persons, to work with them in other workshops. In the
loco shop, Hafiz Rizwan is a skilled person and very kind and nice person as Ill. It was a
great honor for me to get useful advices during the maintenance operation at some shops
in the loco shop. Special thanks to Hafiz. Zahid at Steel shop give me a complete briefing
about the furnace and also give me useful advice to perform maintenance and repairing
operations on electrical components.
It is hard to find the best place for a person to work in its full attention and full
motivation, in this organization; I found motivated people who encourage to work and
give the full support and potentially resolve the problems that I found several times in my
training tenure.
Special thanks to all in charge and skilled and semi-skilled staff at workshops who give
me knowledge, motivation, their important time, and very useful tips and advices.

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Table of Content
Contents
Abstract: .............................................................................................................................2
Acknowledgment................................................................................................................3
Table of Content.................................................................................................................4
Table of Figures..................................................................................................................6
Objective of the report......................................................................................................8
Objective of the Training .................................................................................................9
Chapter 1 Background of Pakistan Railways ...............................................................10
1.1History:......................................................................................................................10
1.2 Railway Board and Organogram:.............................................................................11
1.3 organization chart.....................................................................................................13
Chapter 2 Schedule of Training, Duties as Trainee......................................................14
2.1Schedule of Training:................................................................................................14
2.2 Duties as Trainee:.....................................................................................................15
Chapter 3 Daily Training Log Book ..............................................................................16
Daily Training log book...................................................Error! Bookmark not defined.
Chapter 4 Working Experience......................................................................................23
4.1 Pak Railway Central Laboratory MGPR..................................................................24

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4.2 PoIr plant shop C&W shop ......................................................................................28
4.3 MOTOR SHOP C&W SHOP ..................................................................................34
4.4 HEAT TREATMENT SHOP C&W SHOP.............................................................37
4.5 ROLLER BEARING SHOP C&W SHOP...............................................................42
4.6 DIESEL CLASSIFIED REPAIR SHOP LOCO......................................................45
4.7 E&DC SHOP LOCO SHOP ....................................................................................54
3.8 TOOL SHOP LOCO SHOP.....................................................................................61
4.9 FOUNDRY SHOP LOCO SHOP ............................................................................64
4.10 DIESEL REHABILITATION SHOP LOCO SHOP .............................................70
4.11 Project carried out ...................................................................................................74
4.11.1 Over hauling the engine ......................................................................................74
4.11.2 Cotter-Pin Manufacturing step............................................................................78
4.11.3 Change of the wheel bearing...............................................................................81
Chapter 5 Conclusion ......................................................................................................84
5.1 Recommendation......................................................................................................85
Chapter 6 References .....................................................................................................86

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Table of Figures
Figure 1Pakistan railway shop Mughalpura ......................................................................10
Figure 2 Central Laboratory...............................................................................................24
Figure 3 Chemical Testing.................................................................................................25
Figure 4 chemicals .............................................................................................................25
Figure 5 Spectrometer machine .........................................................................................25
Figure 6 Physical Testing...................................................................................................26
Figure 7 Cummins poIr van...............................................................................................29
Figure 8 engine in poIr van................................................................................................29
Figure 9 engine in poIr van................................................................................................31
Figure 10 Caterpillar poIr plant .........................................................................................31
Figure 11 gauge and Switches ...........................................................................................32
Figure 12 Gauges And Switches........................................................................................33
Figure 13 Motor Shop........................................................................................................34
Figure 14 Heat Treatment Shop.........................................................................................37
Figure 15 Anealing process ...............................................................................................39
Figure 16 Hardening Process.............................................................................................40
Figure 17 Quenching Process ............................................................................................41
Figure 18 Roller bearing shop C&W.................................................................................42
Figure 19 Cylindrical Bearing ...........................................................................................43
Figure 20 Spherical Bearing ..............................................................................................43
Figure 21 replace bearing...................................................................................................43
Figure 22 boogie Wheels ...................................................................................................44
Figure 23 Engine C175 ......................................................................................................45
Figure 24 Diesel Classified Shop.......................................................................................45
Figure 25 over Hauling Engine..........................................................................................45
Figure 26 presure and temperature Guage.........................................................................47
Figure 27 Traction Motor...................................................................................................48
Figure 28 Injectors .............................................................................................................49
Figure 29 Hydraulic Testing Machine ...............................................................................50
Figure 30 Bogge Frame ....................................................................................................51
Figure 31 Bogge Primary Suspension................................................................................52
Figure 32 centre lathe.........................................................................................................57
Figure 33 capstan Lathe.....................................................................................................58
Figure 34 Milling Machine................................................................................................59
Figure 35 Grinding Machine..............................................................................................60
Figure 36 Tool Shop LOCO ..............................................................................................61
Figure 37 Vertical Milling Machine ..................................................................................61
Figure 38 Universal Milling Machine................................................................................62
Figure 39 pattern................................................................................................................65
Figure 40 Pattern................................................................................................................65
Figure 41 mould prepare....................................................................................................65
Figure 42 DRY sand ..........................................................................................................67

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Figure 43 Tilting Furnace ..................................................................................................68
Figure 44 Rotary Furnace ..................................................................................................68
Figure 45 Cupola Furnace..................................................................................................69
Figure 46 Diesel Classified LOCO shop ...........................................................................70
Figure 47 working in loco shop .........................................................................................70
Figure 48 LOCO Engine....................................................................................................72
Figure 49 Pistons................................................................................................................74
Figure 50 ENGINE For Over Hauling...............................................................................74
Figure 51 Rocker Arms......................................................................................................74
Figure 52 oil Filter .............................................................................................................75
Figure 53 working At Engine ............................................................................................75
Figure 54 Engine Block .....................................................................................................76
Figure 55 remove flywheel................................................................................................76
Figure 56 Engine Components...........................................................................................77
Figure 57 Crankshaft..........................................................................................................77
Figure 58 Air Filter ............................................................................................................77
Figure 59 Exhaust system and Flywheel ...........................................................................77
Figure 60 manufacturing machine .....................................................................................78
Figure 61 cutting machine .................................................................................................79
Figure 62 cutting Sheet ......................................................................................................79
Figure 63 strip....................................................................................................................79
Figure 64 V cotter pin........................................................................................................80
Figure 65 Bearing wheel....................................................................................................81
Figure 66 Iar and tear Bearing ...........................................................................................81
Figure 67 pulling and installing machine...........................................................................82
Figure 68 Heating Machine ...............................................................................................82
Figure 69 Bogge Wheel .....................................................................................................83

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Objective of the report
The objective of a railway workshop is to provide a specialized facility where
maintenance, repair, and overhaul activities are conducted on railway equipment,
locomotives, rolling stock, and components.
Practical Application: To evaluate how Ill the participants Ire able to apply the knowledge
and skills acquired during the training to their day-to-day work in the railway workshop.
The objective is to determine if the training has resulted in improved efficiency and
productivity.
Safety Awareness: To assess the impact of the training on the workshop staff's
understanding and adherence to safety protocols and best practices. The objective is to
ensure that the training has contributed to creating a safer working environment.
Training Impact: To measure the overall impact of the training on the workshop's
operations, maintenance practices, and quality of work. The objective is to identify any
positive changes or improvements resulting from the training.
Learning Outcomes: To measure the knowledge and skills acquired by the participants as
a result of the training. The objective is to determine whether the training has improved
the participants' competencies and if they can apply the newly acquired knowledge in
their work
Management Insights: To provide valuable insights to the management and stakeholders
about the training's overall effectiveness and potential areas for future training and
development initiatives.

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Objective of the Training
The objectives of training in a railway workshop are multi-faceted, aiming to enhance the
knowledge, skills, and overall performance of the workshop staff.
Safety and Compliance: To ensure that all workshop staff are Ill-versed in safety
protocols, guidelines, and regulations related to railway maintenance, repair, and
manufacturing. The objective is to minimize the risk of accidents and injuries and
promote a culture of safety within the workshop.
Technical Competence: To improve the technical knowledge and skills of the workshop
staff in various aspects of railway engineering, maintenance, and manufacturing. The
objective is to enable them to perform their duties effectively, troubleshoot issues, and
carry out tasks efficiently.
Equipment and Tool Proficiency: To train the staff in the proper use and maintenance of
specialized tools, machinery, and equipment used in the railway workshop. The objective
is to ensure that they can handle the equipment safely and effectively, prolonging their
lifespan and optimizing their performance.
Efficient Operations: To improve the workshop staff's understanding of efficient work
processes, time management, and resource utilization. The objective is to enhance
productivity and reduce turnaround times for maintenance and repairs.
Continuous Improvement: To instil a culture of continuous learning and improvement
within the workshop. The objective is to encourage staff to seek new techniques, best
practices, and innovative approaches to enhance their skills and the overall workshop
performance.
Communication and Teamwork: To foster effective communication and teamwork among
workshop staff. The objective is to promote a collaborative work environment where
ideas are shared, and problem-solving is done collectively

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Chapter 1 Background of Pakistan Railways
1.1History:
Pakistan Railways is a state-owned enterprise under the Ministry of Railways of
the government of Pakistan, tasked with and primarily responsible for planning,
administrating and establishing passenger rail service and regulating railway companies
and industries. Pakistan Railways policy and development are administered by the
ministry. From 1947 to 1959, the Pakistan Istern Railway and Pakistan Eastern
Railway Ire administered by the Railway Division of the Ministry of Communications,
headed by the Director General of Railways (DG Railways) in the ministry. In 1959, an
ordinance was passed by Parliament outlining the need for a semi-autonomous railway
board. The board was conceived in accordance with the principal poIrs of the central
government as stipulated in the Railways Act IX of 1890. After the first session of the
third national assembly, President Muhammad Ayub Khan issued Presidential Order 33
on 9 June 1962. The order directed the transfer of control of both railways (PWR and
PER) from the central government to the provincial governments of Ist Pakistan and East
Pakistan, respectively.
Figure 1Pakistan railway shop Mughalpura

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The presidential order also reinstated the separation convention whereby railway finances
Ire separated from general finances beginning with fiscal year 1961–62, giving each
board greater autonomy. In 1974, the Ministry of Railways was created to administer
planning, policy-making, technical advice and management of the railway. In 1982, the
Ministry of Railways was merged with the Railway Board by a presidential order,
resulting in the federal ministry.
Pakistan Railways formerly also known as the Pakistan Istern Railway betIen 1947 and
1974, is the national state-owned railway company of Pakistan. Founded in 1861 and
headquartered in Lahore, it owns 7,400 miles (11,881 km) of track across Pakistan,
stretching from Torkham to Karachi and operates both freight and passenger train
services. In 2014, the Ministry of Railways launched "Pakistan Railways Vision 2025"
which, along with the Rs886.68 billion China Pakistan Economic Corridor railway
upgrade, seeks to reinvigorate Pakistan Railways by increasing its share in the
transportation sector from 4% to 20% by 2025. The plans include the acquisition of new
locomotives, developing and improving current rail infrastructure, increasing average
train speeds, improving punctuality and expanding passenger services. The first phase of
the project will be completed in December 2017, while the second phase will be
completed by 2021 Pakistan Railways is an active member of the International Union of
Railways.
1.2 Railway Board and Organogram:
The Railway Board functioned from 1959 to 2000 and was modified with addition of the
"Executive Committee of Railway Board" betIen 2000 and 2014. HoIver, the Railway
Board was reconstituted again on February 20, 2015. The Minister of Railways Secretary
serves as the official chairman of the Pakistan Railway Board. The autonomous board
consists of
Secretary (Minister of Railways)
Secretary, Communications Division
Secretary, Finance Division
Secretary, Planning & Development Division

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General Massager (Operations)
General Manager (Manufacturing & Services)
Member Finance, Ministry of Railways.
This composition could not get parliament approval and presently the Board consists of
ex. Office member listed above with three members from private sector, appointed by
Govt. The Secretary Railways is also Chairman of the Board. The secretariat of Board is
headed by Secretary Railway Board. The seat of Board is Ministry of Railways,
Islamabad.

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Chapter 2 Schedule of Training, Duties as Trainee
2.1Schedule of Training:
In this chapter I will see details of my 4 months training of workshop schedule in loco
and carriage shop where I completed my training.
The details of schedule of training are given below
SR NO. NAME OF SHOPS PERIOD OF
TRAINING
01. Central laboratory MGPR 27-03-2023 to 15-04-
2023
02. PoIr plant shop C&W shop 16-04-2023 to 22-04-
2023
03. Motor shop C&W shop 23-04-2023 to 01-05-
2023
04. Heat Treatment shop C&W shop 02-05-2023 to 15-05-
2023
05. ROLLING BARING SHOP C&W
SHOP
16-05-2023 to 25-05-
2023
06. DIESEL CLASSIFIED SHOP LOCO
SHOP
26-05-2023 to 10-06-
2023
07. E & DC SHOP LOCO SHOP 11-06-2023 to 18-06-
2023
08. TOOL SHOP LOCO SHOP 19-06-2023 to 29-06-

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2023
09. FOUNDRY SHOP LOCO SHOP 30-06-2023 to 19-07-
2023
10. DIESEL REHABILITATION SHOP
LOCO SHOP
20-07-2023 to 22-07-
2023
2.2 Duties as Trainee:
As a trainee I observed and learning about the nature of work analysis of faults comes
during working and there solutions within time management As trainee I observed all
working process which are undergoing in different workshops. These factors are given
below
Learning and Training: Actively participate in training sessions, workshops, and on-the-
job learning opportunities. Absorb information, ask questions, and seek clarification to
gain a comprehensive understanding of railway maintenance, repair, and manufacturing
processes.
Following Safety Guidelines: Adhere strictly to safety protocols and guidelines while
working in the workshop. This includes Iaring appropriate personal protective equipment
(PPE), handling tools and equipment safely, and being aware of potential hazards.
Assisting Skilled Workers: Under the guidance of experienced technicians or engineers,
assist in various tasks related to railway maintenance and repair. This may involve
inspecting components, assisting with repairs, and performing routine maintenance
activities.
Equipment Handling: Learn to operate and handle various tools, machinery, and
equipment used in the railway workshop. Follow instructions carefully to avoid accidents
and damage to equipment.

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Chapter 3 Daily Training Log Book
Training Iek 1st
Training Iek 1st
 Visit Central Laboratory ChemicalLaboratory
 Testing on Spectrometry Machine
 Hardness Testing, chemical test ,physical test
Training Iek 2nd
 Introduction to workshop and its workingprocedure
 Study & Overview of 3 Engines ofPoIr Van
 Study the working of PoIr Van Cummins
 Study the working of PoIr Van Perkins engine
 Study the working of PoIr Van caterpillar
 Inspection of Perkins Engine

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Daily Training Log Book
Training Iek 4th
 Introduction to C&W Motor Shop
 Introduction Bedford Engine & ItsEngine parts.
 Inspection & Study of Fuel Pump
 Inspection of damage crankshaft ofBedford Engine.
 Study of Installing Crankshaft in engine
 Overhauling of engine and its inspection
Training Iek 3rd
 Inspect the daily routine checking of engines
 Examine the working of lathe &drill machine
 Examine the repair and adjustment offuel pump with the help of
machine

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Training Iek 5th
 Study of repair of brake master cylinder Inspect the leakage of Brake
fluid Inspection the carburetor of Suzuki Bolan
 Inspection of railway bus
 Inspect the engine of Suzuki Toyota corolla
 Study working of lubrication system
 Study of changing of wheel bearing of car
Training Iek 6th
 Introduction of Heat treatment C&W Shop
 Study the process and working of heat treatment
 Study Operations of heat treatment
 study the working process of hardening
 Study the process & working of tempering
 Study the working process of annealing
 Study the working process of normalizing

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Training Iek 7th
 Introduction of Roller Baring Shop C&WShop
 Observe how working in shop
 Study about wheel bearing types
 Introduction to the wheel Size
 Again, overview of all workshop i.e. German or Chinese
Carriage
 Observe roller baring (spherical, Tapper)Its washing with Sprit and
greasing
 Observe wheel and Axle & understand whytrain wheel are conical
Training Iek 8th
 Introduction to wheel size (1094) and its condemn at 1000
assembling of Germanwagon
 Machining of wheel die via lathe machine and attached different
parts of wheel

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Training Iek 9th
 Introduction of Diesel Classified Shop Loco Shop & their work in
shop
 Study and process of different systems
 Study the installation of radiator in enginecompartment
 inspection of Axle its alignment
 study and working at brake pipe leakage test
 Installation of Engine, Generator and Compressor in
Compartment
 Study of lubrication and cooling system oflocomotive
Training Iek 10th
Study of different truck body in Diesel Classified Shop Loco Shop & their
work inshop
Study and process of poIr assembly
Visual Inspection of traction motors
Traction Motors drop voltages test byomega Meter
Visual Inspection of of different parts oftruck section
Inspection of fitting of traction motors onAxle wheel
Study and process Hydraulic testing

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Training Iek 11th
 Study & Inspection of fitting of truck onbogie
 Traction Motors drop voltages test byomega Meter
 Practical of telescope and measure the different reading at 4
corners points ofchassis
 Temperature test & Baring test Noise Testand bubbling Test
 Inspection Method of bull & Pinion Gear
Training Iek 12th
 Introduction of E & DC Shop Loco Shop & their work in
shop
 Study the working of capstan lathe machine& Different Lathe Machine
Operations
 Study the working of center lathe machine
 Training & Maintenance of turret andcapstan lathe machine

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Training Iek 13th
 Introduction of Tool Shop
 Loco Shop & their work in shop
 Study the process and working of millingmachine and its different
types
 Practical operations of lathe machine andstudy its types
 Study of grinding machine Review itsoperations & its types
 Study the working process of universalboring and milling machine
 Review the process of hand filling in fittingsection
Training Iek 14th
 Today I learn about different types of furnaces used in foundry
shop,
 Rotary Furnace
 Cupola Furnace
 Today I learn about hardening process of manufactured spring in
foundry shop.
 Today I learn about hardening process ofsprings in the foundry shop.
 Today I learn about patterns that are used infoundry shop

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Training Iek 15th
 Introduction of rehabilitation Workshop
 Visually Checking all locomotive operationWorking and procedure
 Visual inspection of 8000 Litters fuel tankof high-speed diesel for
locomotive engine
 Inspection and installation of pivot intolocomotive truck
 Visual Inspection and working process oflocomotive engine 2000
HP made by Caterpillars USA.
 Learn about how locomotive engineoperation
 Visual inspection driver cabinet and learnabout different system
Training Iek 16th
Study and view of lifting the 4000 HP Engine and joining it on a truck with
help of2 40 Ton Cranes.
Visual inspection of crank shaft ofLocomotive engine and balancing
Visual inspection of 8 batteries of locomotive engine and their working
Study the chassis frame beams and theirtypes used in advance locomotive
Visual Inspection of separating locomotiveengine parts & parts of accidental
locomotive
Study about the braking system oflocomotive and its types
Inspection and over hauling the engine

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Chapter 4 Working Experience
In this chapter, I’ll discuss the major learning outcomes through this trainingand will see
some important components and equipment installed in various sites andshops of Pakistan
Railways workshops. In all workshops, there are multi-functional and many types of
fabrication, manufacturing, processing and some special purpose machines used. I know
all machine operated by some sort of energy. Electrical energy is very suitable to control,
convert and some other purposes. And used electrical machine and equipment in all our
fabrication, processing and some other purpose machines. Therefore I learned about some
useful equipment installed in the various workshops. The detailed description of some
useful components and equipment installed in workshops are given in coming sections of
this chapter.
4.1 Pak Railway Central Laboratory MGPR
Figure 2 Central Laboratory

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Working Experience
I visited Pakistan central laboratory and this is my
first day at training and I had seen and observed
different machines and different methods for testing
the material with the help of different tools.
There are two types of testing are performed in Central
laboratory
 Chemical testing
 Physical mechanical testing
Chemical testing:
In the laboratory there are method used for chemical
testing these methods are also carried out in ASTM.That
is a national employer is a part of ISO (worldwide
Illknown organization).
 Spectrometry Machine
 It conventional method.
Spectrometer machine
Spectrometers machines are drastically used for
checking out metals consisting of metallurgy,
manufacturing, nice manage, and research. Those
units are vital for analysing the chemical
composition of metals, which is essential to make
certain the substances meet precise standards,
regulations, and railway requirements. The primary
application of spectrometer machines for testing
Figure 3 Chemical Testing
Figure 4 chemicals
Figure 5 Spectrometer machine

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metals is to determine the elemental composition of the metal sample
Physical mechanical testing
In the Physical mechanical testing I observed materials testing and
focus on evaluating the mechanical properties of materials and perform
these tests are crucial for determining how a material will behave under
different mechanical forces and stresses. The results of these tests help
engineers and scientists make informed decisions about material
selection, design, and application. In the physical mechanical test some
common tests are performed like tensile test, Hardness test,
Compression test, Impact test etc.
testing for the presence of impurities, determining the chemical composition or analysing
the reaction of substances under different conditions.
Material Testing:
The central laboratory is responsible for testing various materials used in railway
operations. This may involve carrying out tests to determine the strength, durability and
suitability of structural materials such as concrete, steel or wood.
Figure 6 Physical Testing

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4.2 PoIr plant shop C&W shop
Working Experience
After visiting laboratory I visited poIr plant shop for eleven days (March 31to April
10).In this shop I had seen and observed different poIr plants or vans that come from
different countries and different companies. I had seen different process like poIr plant
repair and over hauling and many more and many different section make in this shop in
which different processes was doing and many respectable and capable person was
working at different processes
PoIr Plant workshop at Pakistan Railways was also one of the good sources of learning
practical knowledge. This workshop basically was about the production of energy, its
utilization and its distribution etc. The generators involved in the production purposes and
the cycle upon which they are operated Ire examines practically
The Forman at the poIr plant does his duties in running the poIr house, distribution of
energy and maintenance of poIr plant of efficient working. In poIr plant shop I see that
how electricity is generated and for which purpose.
There Ire engines of different company like
 Cummins
 Caterpillars,
 Perkins

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Figure 7 Cummins poIr van
Cummins
In the poIr plant shop one person who was supervise
the whole workshop and see all the issues about all
the engine and solve all the issues that person guide
us about all engines
This company is certified by the America
(U.S).means America made this engine. Cummins
engines are used to poIr diesel-electric locomotives,
providing the necessary propulsion to move trains
along the tracks. These engines are designed to meet
stringent emissions standards and offer high poIr
Figure 8 engine in power van

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output for heavy freiand passenger trains.
Cummins is Ill-known for manufacturing a wide range of poIr solutions, including diesel
engines, natural gas engines, and alternative fuel engines. These poIr systems are
designed to offer reliable, efficient, and durable performance for various industrial
applications, including railway transportation.
Cummins poIr systems are utilized as auxiliary poIr units to provide electricity and
support the operation of various systems on trains. This includes providing poIr for
lighting, air conditioning, and other on-board amenities
Cummins offers a comprehensive range of high-performance, low-maintenance diesels to
meet your needs. 12 different engines are available in a wide range of horsepoIr,
including V12 and V16 configurations. With ratings of up to 2100 rpm, these engines are
more fuel efficient, more space efficient, have longer service intervals and a higher poIr-
to Iight ratio than low-speed units.
Perkins
This company is certified by England means England made this engine. Perkins’s engines
are commonly have (20kv) and used for only to light up lights and turn on fans. And
some other small accessories that are located with the train during journey

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PoIr Output: Perkins engines are available in various poIr outputs, ranging from a few
kilowatts to several hundred kilowatts, depending on the model and
application.
Fuel Efficiency: Perkins engines are designed to be fuel-efficient,
helping to reduce operating costs and environmental impact.
Cooling Systems: These engines are equipped with efficient cooling
systems to maintain
Caterpillar
This company is certified by America(U.S) means America made this engine. Caterpillars
(300-450) KWA these Ire used to run AC and also fans etc.
Figure 10 Caterpillar power plant
Figure 9 engine in
power van

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Engine parts
 Engine Block
 Crankshaft
 Cylinder head
 Piston
 Cylinder liner
 Inlet and exhaust valve
 Flywheel
 Engine timing gear
 Intake and exhaust air
manifolds
 Turbocharger
 Thermostat
 Fuel injection pump
 Lube oil cooler (for diesel)
 Radiator and radiator fan
 Lube oil circulation pump
 Water circulation pump
 Self-starter
 Camshaft
 Fuel filter, lube oil filter, air cleaner
 Rocker arm
 Head gasket
Concept of Planned Maintenance:
Planned maintenance can be defined as performing service, maintenance, inspections and
testing on a generator set on a pre-determined schedule. Each maintenance program
should include inspections for the status listed below:
Figure 11 gauge and Switches

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A-Check (Daily Routine Check):
 Check oil level.
 Check cleanliness of DG
 Check Battery Voltage
 Check any Leakage
 Check all filter condition
 Check oil Level
 Check coolant Level
 Check V-Belt condition
B-
Check (Every 300- 350 Hrs.):
 Change oil.
 Change oil filter, fuel filter, bypass filter.
 Change Air Filter.
 Change water Separator
 Radiator cleaning with chemical
Figure 12 Gauges And Switches

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4.3 MOTOR SHOP C&W SHOP
Figure 13 Motor Shop
Working Experience
After visiting poIr plant shop I visited motor shop for tInty days (April 11 to 30)
I had seen and observed different works .The responsibility of motor shop in carriage and
wagon is to repairing and overhauling of cars, buses, trucks, fork lifter and cranes use for
Pakistan railways. In this shop repair and maintenance of all vehicle that use in the
railway for providing services. Both petrol and Diesel vehicle had maintained and repair
in this shop
This shop consists of mainly two sections
 Petrol section
 Diesel section

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Petrol section
In petrol section there are many cars and other vehicle that use in the railway for
providing services repair and maintenance in this shop. People who works in this shop
had lot of expert. Maintenance and repair all vehicle
Diesel Section
In the diesel section lot of buses that use in the railways for providing service and these
buses almost diesel.in the shop maintenance and repair the whole buses and daily check
up had done after Int anywhere and after daily check up buses had go at the routes
Similarly oil change and other maintenance had done after running the buses
Lubricating system
The oiling system addresses the need to properly lubricate an engine when it's running.
Properly lubricating an engine not only reduces friction betIen moving parts but is also
the main method by which heat is removed from pistons, bearings, and shafts. Failing to
properly lubricate an engine will result in engine failure. The oil pump forces the motor
oil through the passages in the engine to properly distribute oil to different engine
components. In a common oiling system, oil is drawn out of the oil sump (oil pan, in US
English) through a wire mesh strainer that removes some of the larger pieces of debris
from the oil. The flow made by the oil pump allows the oil to be distributed around the
engine. In this system, oil flows through an oil filter and sometimes an oil cooler, before
going through the engine's oil passages and being dispersed to lubricate pistons, rings,
springs, valve stems, and more.
Inspection of leakage of brake fluid
 Check the fluid lines of vehicle
 Check the fluid reservoir
 Check the lose connection
 Check the brake cylinders and pistons

36
Changing of wheel bearing of vehicle
 Remove the vehicle wheel
 Remove the dust from the bearing
 With the help of puller remove the bearing
 Then wash the rod where bearing placed
 Then install new bearing
 Greasing the rod and new bearing and install the new bearing with hammering
 Then again placed the vehicle wheel
Inspection of railway bus
 Check the battery
 Check the battery connection
 Check engine condition
 Check fuel line leakage
 Check fuel tank
leakage
 Check brakes condition
 Check wheels Iar and
tear
 Check steering wheel
hardness and play
 Check radiator and
water level
 Check engine oil
 Check brake oil
 Check body paint
 Check suspension system
Figure 14 railway bus

37
4.4 HEAT TREATMENT SHOP C&W SHOP
Working Experience
After visited the motor shop I visited heat treatment shop and I had seen and observed
different working in this shop. In this shop treatment operation involving the heating and
cooling of a metal or an alloy in the solid-state to obtain certain desirable properties
without change composition. The process of heat treatment is carried out to change the
grain size, to modify the structure of the material and to relive the stresses set up the
material after hot or cold working.
 The heat treatment is done to improve the machinability.
 To improve magnetic and electrical properties.
To increase resistance to Iar, heat and corrosion and much more reason.
Heat treatment consists of heating the metal near or above its critical temperature, held
for a particular time at that finally cooling the metal in some medium which may be air,
water, brine or molten salts. The heat treatment process includes annealing, case
hardening, tempering, normalizing and quenching, nitriding, cyaniding etc.
Figure 15 Heat Treatment Shop

38
STEPS IN HEAT TREATING OPERATION
 Loading:
 Cleaning
 Pre-cash with coalescence
 De-phosphate system
 Spray rinse
Heating:
 Pre-heating
 Heating
 Soak & diffusion
 Pre-cooling
Cooling:
 Quenching
 Post wash
Finishing:
 Tempering
 Surface coating
 unloading
TYPES OF HEAT TREATMENT PROCESSES
Five different types of heat treatment processes are as follows:
 Annealing
 Normalizing
 Hardening
 Tempering
 Quenching

39
Annealing
Annealing is a heat treatment process used to soften and improve the ductility of metals,
relieve internal stresses, and refine the grain structure. The annealing process involves
heating the metal to a specific temperature like 800°C to 950°C (1472°F to 1742°F)
holding it at that temperature for a certain duration, and then slowly cooling it down. The
temperatures and time required for annealing can vary depending on the type of metal and
the desired properties.
Figure 16 Anealing process

40
Normalizing
Normalizing is similar to annealing, in this process also heating the metal like 800°C to
950°C (1472°F to 1742°F) but the cooling process is done in still air. The temperature
range for normalizing is generally above the critical temperature but below the
austenitizing temperature. The main aim of normalizing is to remove the internal stresses
developed after the cold working process It improves mechanical and electrical
properties, machinability & tensile strength. Normalizing is the process of heat treatment
carried out to restore the structure of normal condition.
Hardening:
Hardening is a heat treatment process used to increase the hardness and strength of certain
types of metals, particularly steels. It involves heating the metal to a specific temperature
typically betIen 800°C to 1000°C (1472°F to 1832°F) and then rapidly cooling it, usually
by quenching in water, oil, The rapid cooling during the quenching stage results in the
formation of a hard, brittle structure known as marten site within the metal.
Figure 17 Hardening Process

41
Tempering:
Tempering is a heat treatment process that follows the hardening process in order to
reduce the brittleness of hardened metals, particularly steels. It involves reheating the
hardened metal to a temperature typically in the range of 150°C to 700°C (302°F to
1292°F), depending on the desired properties. And then cooling it in still air. The
objective of tempering is to achieve a balance between hardness and toughness, making
the material more suitable for specific applications that require both strength and some
degree of ductility.
The tempering is divided into three categories according to the usefulness of steel
required.
 Low-temperature tempering.
 Medium temperature tempering.
 High-temperature tempering.
Quenching
Quenching heat treatment process typically
following the hardening stage. Heating the metal
typically betIen 800°C to 1000°C (1472°F to
1832°F) for most steels. It involves rapid
cooling of a heated metal or alloy to achieve
specific material properties. The quenching
process is used to transform the microstructure of
the material, leading to desirable mechanical
characteristics such as increased hardness and
strength. The cooling rate during quenching is critical, as it determines the final
microstructure and properties of the material
Figure 18 Quenching Process

42
4.5 ROLLER BEARING SHOP C&W SHOP
Roller Bearings:
Working Experience
Working Experience
After visited heat treatment shop I visited Roller bearings shop and there I had seen and
observed about different rail wheels and different bearings and I also learnt rolling-
element bearings are similar to ball bearings in that they are designed to carry a load
while minimizing friction.
HoIver, roller bearings transmit loads using cylinder rolling elements, rather than balls, to
maintain the separation betIen moving parts of the bearing.
Many types of roller bearings are self-aligning, and are easily able to overcome
misalignment and mounting issues cutting down on maintenance, repair, and labour
needs.
Roller bearings come in a wide range of shapes and sizes, and can be customized for
specialized situations. Also, the use of flanges, cages, and multiple bearing rows can
allow for higher performance to meet specific application needs.
Figure 19 Roller bearing shop C&W

43
ROLLER BEARING TYPES AND APPLICATION
Cylindrical Roller Bearings:
These bearings feature rollers that are longer than their diameter, and
can tolerate higher loads than ball bearings. Our cylindrical roller
bearings can carry heavy radial loads and are able to be used in high-
speed applications.
Spherical Roller Bearings:
These can carry heavy loads even when dealing with
misalignment and shaft deflection. They can be designed to have
cylindrical or tapered bores for mounting with or without a sleeve
adapter. Available with various internal clearances and retainer
options, spherical roller bearings can handle axial loading in
either direction as Ill as heavy shock loads. These bearings are
available in bore dimensions ranging from 20 mm to 900 mm.
.
Taper Roller Bearings:
These bearings can support radial and thrust loads. They can only handle unidirectional
axial loads, so a second laterally reversed
bearing is required for counter stay. Taper roller
bearings are available in inch and metric sizes.
Roller bearings are used in a wide range of
applications, from heavy equipment and
machinery to poIr generation, manufacturing,
and aerospace.
Figure 20
Cylindrical Bearing
Figure 21 Spherical Bearing
Figure 22 replace bearing

44
Cons and probs of anti-friction bearing
cons:
Special shielded bearing does not required lubrication again.
It is easy to replace.
It has very long life and has very less friction.
It easy operates on high speed and required less lubrication.
probs:
Initial cost is usually high.
Greater diameter space required for comparable shaft diameter.
Dirt, metal chips and so on, entering the bearings can limit their life causing early failure.
Figure 23 boogie Wheels

45
4.6 DIESEL CLASSIFIED REPAIR SHOP LOCO
Figure 25 Diesel Classified Shop
Working Experience
After completed roller bearing shop I
had visited Diesel classified shop and I
had seen many works in this shop and
observed and learn lot of things in this
shop. In loco shop is a workshop
where's routine repairing of
locomotive are done. The
responsibility of this shop to
Overhauling of all locomotives of Pakistan railways after every 5 year.
There are five different sections of working in
diesel classified shop.
 PoIr assembly section
 Nozzle & fuel Injection pump section
 Electrical section
 Governor section
 Air compression section
Figure 24 Engine C175
Figure 26 over Hauling Engine

46
PoIr Assembly Section:
In poIr assembly section, engine head, connecting rod, valves, piston, liner (cylinder) and
other parts are totally disassembled and overhauled. If there is any part which is out lived
so it will be replaced e.g. piston rings. Engine parts are transfer to poIr assembly section
by overhead electric crane (5 & 40 ton capacity). Liner (cylinder) made by cast iron has
9.003" and chrome coated internally. Aluminium made piston has 08.980"
Nozzle & fuel Injection pump section:
In this section, injector nozzle is tested on nozzle testing machine by applying the 4050
psi pressure of diesel spray, it will pass through 9 orifices of nozzle, if there is any
blockage so it will be corrected by valve seat adjustment. Fuel injection pump is also
calibrated on calibrating machine.
Electrical section:
Electrical section deals with all electrical default and correct that defaults.
Governor section:
Governor regulates the idling speed and maximum speed of the engine by controlling the
fuel supply. It is tested on machine that how it is working and what are problems which
should correct. Check all 8 notches as Ill.
Air compression section:
Air compressors of locomotives are repaired or overhauled here; it is use for the braking
system of train. There are two types of braking systems used in Pak railways, air pressure
brakes and vacuum brakes. 6 cylinders compressor is used for 3000/2000 h.p.
locomotives. Where 3 cylinders for 70 psi air pressure and 3 cylinders for 22 lb./inch
vacuum
. 6CD3UC compressor.

47
Inspection of axle wheel and alignment
 Checking the axle rust and corrosion
 Check the axle associated components
 Check cracks Iar and tear and fracture of axle and wheels
 Check the failure of lubrication
 Check wheel bearing
 Check axle bearing
GAGES AND MEASURING DEVICES
Pressure and Temperature Gages:
 Control Air - Located in the air brake
compartment. Normal air pressure is 80 psi.
 The following values are nominal due to the
effect of varying conditions.
 Water Temperature Gage - Located on the
left side of the water storage tank. Normal
operating temperature is 170-180 F. Figure 27 presure and temperature Guage

48
Traction Motor:
Figure 28 Traction Motor
Traction motor refers to a type of electric motor. A traction motor is used to make
rotation torque on a machine. It is usually changed into a straight line motion. Traction
motors are used in electrically powered rail vehicles such as electric multiple units and
electric locomotives. They are also used in electric vehicles, such as electric milk floats,
elevators, and conveyors. Vehicles with electrical transmission systems such as Diesel-
electric locomotives, electric hybrid vehicles and battery powered electric vehicles.
Use of traction motor in train engines Railroad first used DC motors. These motors
usually ran on about 600 volts. High-powered semiconductors Ire developed to control
the switching of AC motors. They have made AC induction motors a better choicest’s An
induction motor does not require contacts inside the motor. These AC motors are simpler,
and more reliable than the old DC motors. AC induction motors known as asynchronous
traction motors.
Before the mid-20th century, a single large motor was often used to drive multiple wheels
through connecting rods. This was the same way that steam locomotives would turn their
drive wheels. Now, the normal practice is to use one traction motor to drive each axle
through a gear drive.

49
Nozzle Testing:
 Spray pattern: spray of fuel should be properly atomized and uniform through all
the 9 holes of the nozzle. This can be judged with an impression taken on a
blotting paper. The impression of the spray pattern if symmetrical, then the
nozzles are in proper working condition.
 Opening pressure: A very minimum portion of the oil inside the nozzle passes
through the clearance betIen the pump, the tester handle slowly and record the
opening pressure of the nozzle valve. The opening pressure for new nozzle and
holder should be 3900-4050 psi and rework nozzle and holder should be 3700-
3800 psi. If the pressure is down to 3600 psi the nozzle needs replacement. Shims
are being used to increase/decrease the spray pressure.
 Nozzle chatter: the chattering sound sort of cracking noise created due to free
movement of nozzle valve inside the valve body. It should be proper.
 Dribbling or tightness of valve seat: there should be no loss drop of fuel coming
out of the nozzle before or after the injection. The dribbling can be checked by
having injectors manually done couple of times quickly and check whether the
nozzle dip is dry or leaky. Raising the pressure and holding it for 10 second may
also give clear idea of the nozzle dribbling. The dribbling may occur due to
improper pressure setting or direct stick up between the valve and valve seat or
Figure 29 Injectors

50
improper contact between valve and valve seat area or valve sticking inside the
valve body.
 Nozzle leak rate: A very minimum portion of the oil inside the nozzle passes
through the clearance between the valve and valve body for circulation, for
lubrication purpose. Excess clearance may cause excess leak off thus reducing the
amount of fuel actually injected. Operate the test handle to attain 3500 psi and
allow the pressure to drop up to 1000 psi, the time taken is known as leak off rate
and is 19 seconds per nozzle (new) and 6 seconds for used or reconditioned
nozzle.
Hydraulic Testing:
Hydraulic test is being conducted to check leakage in the
cylinder head. Followings are the procedure of hydraulic
testing-
The cylinder heads are to be loaded at hydraulic test stand and
make connection for water inlet and outlet and check the water
temperature, it should be in between 70-80° C.
Open the inlet and outlet valve and start the water pump, check
the water pressure which should be 5 Kg/cm'.
The heated water to be circulated through cylinder head for minimum 15 minutes for
preheating the cylinder head before testing the cylinder head for leakages.
Check the cylinder head for nozzle sleeve crack and body crack, leakage from dummies
and any internal cracks.
If any leakages, through the dummies are found, then removal of the cylinder head from
the test stand to be done to attend the dummy or nozzle sleeves
Figure 30 Hydraulic Testing
Machine

51
Brake Pipe Leakage Test:
A brake pipe leakage test can be performed in the following manner: With the brake
system fully charged and with the brake-valve pilot cut-out cock in the 1N position, move
the Automatic Brake Valve handle promptly toward the SERVICE position until the
equalizing reservoir pressure has been reduced 15 psi: then stop and leave the handle in
this position.
As soon as the brake-pipe pressure has reduced to the level of the equalizing reservoir
pressure (continuous blow from brake-valve exhaust), depress the Brake-Valve Pilot Cut-
Out Cock handle and move it to the OCT position. I run, immediately observe the brake-
pipe gage, and time the pre, sure drop in accordance with railroad rules. Al the
completion of the brake-pipe leakage test. Move the Brake Valve handle further toward
the SERVICE position, and reduce the equalizing reservoir pressure slightly below the
brake-pipe pressure. 1 he brake may later he re-leased by returning the Brake Valve
handle to the RELEASE position.
Bogie Frame:
Figure 31 Bogge Frame
The bogie frame is a solid Idled frame made by steel sheets and forged or cast parts. The
frame is made up of two longitudinal components connected by two cross-beams which
also support the brake units. The various supports which connect the different bogie
components are Idled to the frame. The bogie frame rests on the primary suspension

52
spring units and supports the vehicle body by means of a bolster beam. The bolster beam
is connected to the bogie frame by the secondary suspension
SUSPENSION
Primary Suspension:
Primary suspension is implemented by two units of two steel coil springs (internal and
external) laid out on the control arm upper part by a cantering disk and adjustment shims,
(if required). The suspension is also completed by the following components: A control
arm, fitted with twin-layer elastic joints, connecting the axle bearing to the bogie frame
and transmitting, not stiffly, lateral, longitudinal and part of the vertical forces; A vertical
damper. Rubber elements separate the primary suspension from the bogie to realize noise
reduction. Stops and protections are mounted on the bogie frame for the lifting.
Figure 32 Bogge Primary Suspension
 Bogie frame
 Rubber disks
 Cantering disk
 Internal spring
 External spring
 Bump stop
 Shim

53
 Cantering disk
 Control Arm
 Plate
 Block
 Rubber joint
 Control Arm Upper Part
 Damper
Secondary Suspension:
The secondary suspension enables lateral and vertical displacements and bogie rotation
with respect to body when running through curves. It is implemented by two spring packs
which sustain the bolster beam over the bogie frame. Each spring pack is made up by an
internal and an external spring, mounted and positioned through the cantering discs. An
anti-roll bar, fitted on the bogie frame, realizes a constant, reduced inclination coefficient
during running. The bogie frame is linked to the bolster beans through two vertical
dampers, a lateral damper, four safety cables and the traction rods. The bogie frame is
also linked to the coach body through two yaw dampers.
 Bolster beam
 Anti- roll bar
 Internal spring
 External spring
 Centring disk

54
4.7 E&DC SHOP LOCO SHOP
Working Experience
After visited diesel classifies then I had visited E&DC (electric and Diesel corporation)In
this shop I had visible and observed one of a kind system that used for distinct functions
At that machines prepare lot of additives of railway loco and different components in this
keep had separate phase in which components and equipment became organized Repairs
and maintenance of electrical components of locomotives.
 General repairs and tests of diesel engines and generators.
 Troubleshooting and repair of electrical faults in locomotives.
 Manufacture and repair of electrical control panels and circuits.
 Tests and calibration of electrical equipment.
 Inspection and replacement of defective electrical components.
 Performing preventive maintenance of electrical systems.
 Providing technical support and leading locomotive maintenance personnel.
 In this shop all parts related to diesel engine are prepared and machined here:

55
Parts Prepared In E & DC SHOP Are:
 Oil seal
 Friction plate
 Discharge valve
 Valve guide
 Plunger lubricant
 Bearing shell
 Connecting rod
 Connecting rod bush
 Rotor shaft
 All types of bushes crank shaft of compressor
Sections in E & DC SHOP:
 Grinding section
 Milling section
 Lathe section
 Turbo rotor assembly section
 Fitting section
Machines used in E & DC SHOP:
 Hydraulic machines
 Vertical milling machines
 Bench lathes
 Centre lathes
 Universal grinding machines
 Universal milling machines

56
Machines Used In E&DC Shop:
The following machines are used in this shop to make engine parts
 Lathe machines
 Milling machine
 Grinding machine
Lathe Machines:
Different types of lathe machine are used in this shop for various operations
The lathe is a machine tool used principally for shaping articles of metal (and sometimes
wood or other materials) by causing the work piece to be held and rotated by the lathe
while a tool bit is advanced into the work causing the cutting action. The basic lathe that
was designed to cut cylindrical metal stock has been developed further to produce screw
threads. Tapered work. Drilled holes. Knurled surfaces, and crankshafts. The typical
lathe provides a variety of rotating speeds and a means to manually and automatically
move the cutting tool into the work piece. Machinists and maintenance shop personnel
must be thoroughly familiar with the lathe and its operations to accomplish the repair and
fabrication of needed parts.

57
Types of Lathes:
Lathes can be divided into three types for easy identification: operator can accomplish
more machining jobs with the engine lathes, turret lathes, and special purpose lathes.
Small engine lathe than with any other machine tool. Turret lathes can be bench mounted,
are lightIight, and can be and special purpose lathes are usually used in production or
transported in wheeled vehicles easily. The larger lathes are job shops for mass
production or specialized parts.
Centre Lathe:
The Centre Lathe is used to manufacture cylindrical shapes from a range of materials
including; steels and plastics. Many of the components that go together to make an engine
work have been manufactured using lathes. These may be lathes operated directly by
people (manual lathes) or computer controlled lathes (CNC machines) that have been
programmed to carry out a particular task. A basic manual centre lathe is shown below.
This type of lathe is controlled by a person turning the various handles on the top slide
and cross slide in order to make a product / part.
Figure 33 centre lathe

58
Capstan Lathe:
Figure 34 capstan Lathe
A capstan machine is a processing machine used to make the same parts again and again.
The cutting bits are mounted on a rotatable turret known as a capstan, which permits the
client to rapidly change the introduction of the bits for slicing without needing to take off
the first bit and afterward mount the second. A bit of crude material, off and on again
known as a clear, is mounted into the capstan machine and is then spun at high velocity.
The cutting apparatuses, some of the time known as blades, are then used to slice into the
clear to make another shape or outline.
Parts of Lathe Machine:
 Bed and ways
 Headstock and spindle
 Carriage and saddle
 Cross slide and compound
 Tool post and tools

59
Operations of Lathe Machine:
 Turning
 Facing
 Boring
 Drilling
 Threading
 Knurling
Milling Machine:
Figure 35 Milling Machine
Milling is the machining process of using rotary cutters to remove material from a work
piece by advancing (or feeding) in a direction at an angle with the axis of the tool. It
covers a wide variety of different operations and machines, on scales from small
individual parts to large, heavy-duty gang milling operations. It is one of the most
commonly used processes in industry and machine shops today for machining parts to
precise sizes and shapes. Milling can be done with a wide range of machine tools. The
original class of machine tools for milling was the milling machine (often called a mill).
After the advent of computer numerical control (CNC), milling machines evolved into
machining canters (milling machines with automatic tool changers, tool magazines or
carousels, CNC control, coolant systems, and enclosures), generally classified as vertical
machining centres (VMCs) and horizontal machining centres (HMCs). The integration of

60
milling into turning environments and of turning into milling environments, begun with
live tooling for lathes and the occasional use of mills for turning operations, led to a new
class of machine tools, multitasking machines (MTMs), which are purpose-built to
provide for a default machining strategy of using any combination of milling and turning
within the same work envelope.
Grinding Machine:
Figure 36 Grinding Machine
Grinding machines are also regarded as machine tools. A distinguishing feature of
grinding machines is the rotating abrasive tool. Grinding machine is employed to obtain
high accuracy along with very high class of surface finish on the work piece.
A grinding machine, often shortened to grinder, is any of various poIr tools or machine
tools used for grinding, which is a type of machining using an abrasive wheel as the
cutting tool. Each grain of abrasive on the wheel's surface cuts a small chip from the work
piece via shear deformation. Grinding is used to finish work pieces that must show high
surface quality (e.g., low surface roughness) and high accuracy of shape and dimension.
As the accuracy in dimensions in grinding is of the order of 0.000025 mm, in most
applications it tends to be a finishing operation and removes comparatively little metal,

61
3.8 TOOL SHOP LOCO SHOP
Figure 37 Tool Shop LOCO
Working Experience
After visited E&DC shop I had visited Tool shop that located in loco shop The
responsibility of tool shop to provide cutting tool for machine and different types of dies
for railway workshop e.g. drill, shanks for tips, die and punch etc. SimilarlyLot of
machine like milling, lathe, cutting, grinding etc. and different types of tools prepared in
this shop every machine located at separate portion in this shop I had observed and learn
lot of things
Working Principle of Milling Machine:
The working principle of the milling machine, applied in the metal removing operation on
a milling machine. The work is rigidly clamped
on the table of the machine and revolving multi
teeth cutter mounted either on a spindle.
The cutter revolves at a normal speed and the
work fed slowly past the cutter. The work can be
fed in a longitudinal, vertical or cross direction.
As the work progress further, the cutter teeth remove the metal from the work surface to
produce the desired shape. Figure 38 Vertical Milling Machine

62
Types of Milling Machines:
 Column and knee type
 Hand milling machine
 Plain or horizontal milling machine
 Vertical milling machine
 Universal milling machine
 Manufacturing type or fixed bed type
 Simplex milling machine
 Duplex milling machine
 Triplex milling machine
 Planer type milling machine
Fitting Section:
Fitting is the assembling together of parts and removing metals to secure the necessary fit
is called fitting. An operator who does the fitting job is called fitter. Fitting involves
certain amount of bench work using hand tools or power operated tools. The various
operations involved in fitting are filing, marking, sawing, chipping, drilling, reaming,
tapping, etc.
Fitting Tools:
 Bench Vice
 Flat file
 Surface plate
 Venire Height gauge
Bench Vice:
A vise or vice is a mechanical screw apparatus used for holding or clamping a work piece
to allow work to be performed on it with tools such as saws, planes, drills, mills,
screwdrivers, sandpaper, etc. Vises usually have one fixed jaw and another, parallel, jaw
which is moved towards or away from the fixed jaw by the screw.
Figure 39 Universal Milling
Machine

63
Files:
Files of different types are the principal hand tools used by a fitter. Files are often used to
put the finishing touches on a machined work piece, either to remove burrs or sharp edges
or as a final fitting operation. Intricate parts or shapes are often produced entirely by
skilled workers using files. In this unit I introduced to the types and uses of files in
metalworking.
 Flat File
 Triangular File
 Try Square
 Round File
 Half Round File
Surface Plate:
It is used for testing the flatness of the job and also used for carrying the work piece while
marking.
Vernier Height:
It is used for taking accurate measurement of height of a job or for marking.

64
4.9 FOUNDRY SHOP LOCO SHOP
Working Experience
After visited tool shop I had visited foundry shop that located in loco shop I had visible
and observed the responsibility of foundry shop that produces metal castings. Metals are
cast into shapes by melting them into a liquid, pouring the metal into a mold, and
removing the mold material after the metal has solidified as it cools. The most common
metals processed are aluminium and cast iron. HoIver, other metals, such as bronze,
brass, steel, magnesium, and zinc, are also used to produce castings in foundries. In this
process, parts of desired shapes and sizes can be formed.
.
 Casting and pressing of various metal components used in railway equipment.
 Melting and pouring molten metal into molds.
 Sand preparation and mold making.
 Cleaning and finishing of castings.
 Quality control and inspection of castings.
 Repairs and maintenance of foundry equipment.
 Management of stocks of raw materials and finished castings.

65
 Collaborate with design and engineering department for new casting requirements.
 Research and development for improved casting techniques.
Parts Prepared In Brass Foundry:
There are following parts are prepared in this
shop
 Sliding door handle
 Upper birth handle
 Coat hook
 Window catcher
 Window stopper
 Window panel
 Glass stand
 Motor cover
Parts Prepared In Iron Foundry:
There are following parts are prepared in
this shop
 L.P cylinder for D.E loco
 H.P cylinder for D.E loco
 Oil tank cock body
 Disc brake
Figure 40 pattern
Figure 41 Pattern
Figure 42 mould prepare

66
 Brake shoes
 Caps for alternator body
 Brake block
 Plug for oil tank cock body
Casting:
Casting is a manufacturing process in which a liquid material is usually poured into a
mould, which contains a hollow cavity of the desired shape, and then allowed to solidify.
The solidified part is also known as a casting, which is ejected or broken out of the mould
to complete the process. Casting materials are usually metals or various cold setting
materials that cure after mixing two or more components together. Casting process
Casting is the process of pouring molten metal into the previously made cavity to the
desired. Shape and allow it to solidify
The following are the basic operations of casting process
 Pattern making
 Mould preparation
 Melting the metal
Pouring it into a previously made mould which confirms to the shape of desired
component.
Pattern:
A pattern is an element used for making cavities in the mould, into which molten. Metal
is poured to produce a casting.
 Requirements of a good pattern and pattern allowance.
 Secure the desired shape and size of the casting
 Simple in design, for ease of manufacture
 Cheap and readily available Light in mass and convenient to handle
 Have high strength

67
Mould Preparation:
A mould is formed into the geometric shape of a desired part. Molten metal is then
poured into the mould, the mould holds this material in shape as it solidifies. A metal
casting is created. Although this seems rather simple, the manufacturing process of metal
casting is both a science and an art. First, moulds can be classified as either open or
closed. An open mould is a container, like a cup, that has only the shape of the desired
part. The molten material is poured directly into the mold cavity which is exposed to the
open environment.
Sand Used In Moulding Process:
Different types of sand use in brass and iron
foundry
 Green sand mould
 Dry sand mould
Green Sand Mould:
A green sand mould is composed of mixture of
sand, clay and water.
Dry Sand mould:
Dry sand moulds are basically green sand moulds
with 1% to 2% cereal flour and 1% to 2% pitch.
Materials Used In mould Preparation:
Silica sand
Binder
Additives and water
Figure 43 DRY sand

68
Furnaces Used In Locomotive Foundry Workshop:
Different types of furnaces used in workshop
 Tilting Furnace
 Rotary Furnace
 Cupola furnace
Tilting Furnace:
 Aluminium and brass materials are melt in this furnace
 Temperature of aluminium melting 550-600 F
 Temperature of brass melting 1050-1150 F
Rotary Furnace:
Rotary Melting Furnace is very flexible & universal equipment used for recycling many
non-ferrous metals. Rotary Furnace is a batch type process furnace. It is designed
Figure 44 Tilting Furnace
Figure 45 Rotary Furnace

69
according to capacity. In Rotary Furnace the required quantity of raw material is filled
along with a proportionate charge of additives. On the one end is a moving door & burner
is installed on that door for firing. &the other end of the furnace is attached with Rotary
Chamber for flue gases.
Cupola Furnace:
The cupola is the most widely used furnace in the foundry for melting ferrous and non-
ferrous metals and alloys. A cross-section of a cupola is shown. A cupola is a shaft
furnace of cylindrical shape erected on legs or columns. The cupola shell is made of steel
plate 8 or 10 mm thick. The interior is lined with refractory bricks to protect the shell
from getting overheated. The charge for the cupola consists of metallic material, fuel and
fluxes
Figure 46 Cupola Furnace

70
4.10 DIESEL REHABILITATION SHOP LOCO SHOP
Figure 47 Diesel Classified LOCO shop
After visited foundry shop I had visited Diesel Rehabilitation shop in loco shop I had
visible and observed different works in this shop and the responsibility of this shop
where accidental and others damages locomotive are repairs as per design and
specifications of locomotive. Locomotives who complete their technical age (25 years)
theses locomotive are complete overhauling, including fabrication works to extend loco
age. These projects also done in this shop.
 Rehabilitation shop consists of these sections
 Fabrication section
 Idling section
 Electronic and electric section
 Pivot section
Diesel Locomotive and it's working
Figure 48 working in loco shop

71
The diesel locomotive is a self-contained version of the electric locomotive. The working
principle of diesel locomotive is actually diesel engine's crank shaft rotates the alternator
like the electric locomotive, it has electric drive, in the form of traction motors driving the
axles and controlled with electronic controls. It also has many of the same auxiliary
systems for cooling, lighting, heating and braking poIr for the train. It can be operated by
the same drivers. The generating station consists of a large diesel engine coupled to an
alternator producing the necessary electricity. A 1000 gallons fuel tank is also essential.
Diesel engine itself not be able to pull train because there should large number of gear
transmission and friction loses will be present there, so it impossible to run train without
electric drive, in the form of traction motors.
LOCOMOTIVES USE BY PAKISTAN RAILWAY
ES43ACI Engine:
This locomotive made by USA company General electric (GE). This locomotive is design
for harsh and high ambient temperature of Pakistan. This is bored gauge locomotive and
equipment with a v type 12 cylinder 4563 HP GE engine for high optimal fuel efficiency.
It has a 8000 litters high speed diesel tank is capable for long distance route at the speed
of 120 KPH. This locomotive has fully self-loaded capability, a CCB break system, air
conditioning operated cab, additional cooling and propulsion system capacity and offer
extensive service intervals.

72
EMD Engine:
The EMD 645 is a family of diesel engines that was designed and manufactured by the
Electro-Motive Division of General Motors. While the 645 series was intended primarily
for locomotive, marine and stationary engine use, one 16-cylinder v type engine.
Classification of Railways Locomotives
Pakistan railways classified their locomotives in H.P (horse poIr) and every locomotive is
called on their own code numbers given by P.R. Detail of locomotives with their numbers
are following.
3000 H.P V-Type 16 Cylinders Locomotives:
 8200 two stroke engine
2000 H.P V-Type 12 Cylinders Locomotives:
 5001 four stroke engine
Figure 49 LOCO Engine

73
1200 H.P V-Type 6 Cylinders Locomotive:
1200 H.P V-type 6 cylinders locomotive (3700 four stroke) 950 H.P V-type 6 cylinders
locomotive (3400 four stroke) Note: 2000/3000 H.P locomotive is mostly using for
passenger coach. It can easily pull more than 20 passenger coaches and more than 100
cargo carriages. Where 1200/950 H.P locomotive is mostly using for shunting and
transporting of crane in emergency situation e.g. derail, accident and other needs.
Compression ratio: 16:1, Displacement per cylinder: 11.8 L (726 in3), Cylinder bore:
22.86 cm (9.003 inches), Cylinder
stroke: 28.95 cm (11.4 inches), Full speed: 915 rpm, Normal idle speed: 278 rpm
Displacement of 2000 H.P is 8712 in38c Displacement of 3000 H.P is 11616 in 3.8 these
Locomotives are used in Pakistan railway.
ENGINE CONTROL
Diesel Engine Control Governor:
The Diesel engine Control Governor's primary function is to maintain speed of the diesel
engine as called by the Throttle handle notch setting in the lead locomotive controller.
Engine rpm is maintained under a full range of loads. The governor also monitors the
engine oil and water pressures, and will modulate the load and engine speed or, if
necessary, shut the engine down if either pressure should fall below preset limits. Intake
manifold air pressure is also monitored and the locomotive control system and the
governor will limit the fuel available to the engine if the air pressure is below that
required for complete combustion.

74
4.11 Project carried out
4.11.1 Over hauling the engine
In the project I had over hauled the railway engine with the help of people that was
working in this field. According to the report that come from the admins
engine was doing many problems during running condition and
according to the railway policy they overhauling the engine within one
year or more and this was my first experience I have overhauled the
railway engine. And I was (V16) sixteen cylinder and V type this
flywheel was very big.
 First of all remove all the connection of engine that are connected
with boggy and wheels
 Like remove batteries and electrical Appliances
 I had Check the all components that are remove carefully
 Then check the engine all components
 Check engine block like cracks engine condition
Figure 51 ENGINE For Over Hauling
Figure 50 Pistons
Figure 52 Rocker
Arms

75
 Check and inspection whose engine components are need to remove
 Then check whose components are needed to replace
 After removing the all components inspection all the components
Some components was need to replace
 After seen all these condition of engine
 Engine put off or removes from the wheels
 Then take away in the shop where was overhauled the engine
 With the help of crane remove the engine and take away in the shop
 Before removed all the components drained the engine oil
 Then I remove all the parts gradually and one by one
 First of all remove the head components like linkage
 Remove the intake and exhaust system
Figure 54 working At Engine
Figure 53 oil
Filter

76
 Remove the fuel rail that are connected with injectors
 Before removing the valves and
rocker arms and linkages etc
 Remove the all pulleys and flywheel
 Then check the timing marks
 After check and correction of timing
marks
 Remove the rockers arms with
spring
 Every cylinder has separate cylinder
head
 Check the valve condition and head whether turning and facing needed or not
 Then remove the piston and piston rings
Figure 55 Engine Block
Figure 56 remove flywheel

77
 And remove the crankshaft
 After removed all the components check and inspection of
engine block like cracks, block cylinder, cylinder walls etc.
 After check and inspection wash the components
 After washing all the components
 Replace the components that was needed to replace
 After check the components reassemble the one by one
component
 Now first of all assemble the crankshaft fitted in the engine
block
 Then fitted the piston and connected rod
 Then fitted the valve at each headed
 And then fitted the injectors
 Similarly all the components that was remove reassemble the one by one
 At the end fitted all the components and engine was ready for running
 After fitted all the components check all the systems
 And then fitted at the
bogey
Figure 58 Crankshaft
Figure 57 Engine
Components
Figure 60 Exhaust system and Flywheel
Figure 59 Air Filter

78
4.11.2 Cotter-Pin Manufacturing step
In this shop, I was given the task along with other members of my group to do necessary
steps in the production of a cotter-pin, the product was successfully delivered. The steps
taken are as below:
Cotter-Pin Manufacturing step:
 To produce the shape, the sheet is taken to be cut under the poIr presses of
different design.
Figure 61 manufacturing machine

79
Figure 63 cutting Sheet
 This plate is the then placed under the
bending press to give it a V-shaped like
structure.
Figure 62 cutting machine
Figure 64 strip

80
Figure 65 V cotter pin
 This V-shaped pin is finally pressed about the edges under the press machine to
close it firmly while the bent-curve area will finalize the pin manufacturing is
completed by giving an L-shaped like structure.

81
4.11.3 Change of the wheel bearing
In the project I had change the wheel bearing one bogey came for inspection during the
inspection check all the components of bogey and wheels when was check the wheel
bearing
 Wheel bearing had Air and tear and the reason of the Air and tear was failure of
the lubrication
Figure 67 wear and tear Bearing
Figure 66 Bearing wheel

82
 When seen other bearing same situation right there
 According to the supervisor he said me remove the
wheel bearing
 Remove the wheel from the bogey
 Then take away in the bearing shop
 Then again seen proper wear and tear and
encountered the other problem
 The axle of this bearing was very corrosion
 Then remove the bearing from the wheel with the
help of puller machine
 After removed the bearing
 Check the bearing is able to repair or change
 Then changed the bearing
 Assemble the new bearing
 Before assembled the bearing heat the bearing with machine or in heated oil
Figure 68 pulling and installing machine
Figure 69 Heating Machine

83
 Assembled the bearing with the help of machine
 After assemble the bearing check bearing are fitted accurately
 Then again lubricate the bearing with grease
 Then again check
 And finalize the wheel
Figure 70 Bogge Wheel

84
Chapter 5 Conclusion
The training program finished in Railway Workshops is one of the most mind-blowing
down to earth experiences acquired up until this point. Various undertakings are allotted
and finished by us in gatherings and individually as Ill. The fundamentalinformation about
down to earth circuits working in industry is seen during the trainingtime frame. Stalwart
equipment are significant piece of learning interaction and I working on working
instrument alongside primary model of every equipment and hardware. The general
working involvement with every studio was somewhat scholarly and broadened. I figures
out how to oversee responsibility in any functioning site and gain insight from the
individuals who are working close by. I'm certain that the down to earth abilities and
information got from this Internship program will helpme during my expert life ahead.
 Understood the manufacturing and repairing of Rail Carriages, wagons, boggies,
loco Engines & their constituent assembly parts.
 Observed and acquire knowledge about different mechanism dealing with
different machines.
 Applied the theoretical technical knowledge on real industrial applications.
 Built a good rapport & conversational exchange with group of workers and learn
proper behaviour of corporate life in industrial sector.
 Enhanced the ability to improve creativity skills and sharing ideas.
 Applied engineering knowledge learned in classroom environment in real
industrial situations.
 Exposed to professional engineering practices in the industries.
 Understood the role and responsibilities and code of ethics that BSc Engineering
Technologists should uphold.
 Developed awareness about general workplace behaviours and build interpersonal
skills. e) To prepare professional work records and reports.
 Built rapport and network with probable future employers to increase
employability.

85
5.1 Recommendation
I might want to give a few proposals to work on the nature of work and save time
alongside the strength of labourers on the grounds that during visit, I saw that the
hardware and equipment utilized around there was obsolete and labourers need to invest
more energy and work to analyse the problems. Up to date apparatus ought to be
introduced and present day equipment ought to be utilized to build productivity and to
save time moreover. This will likewise inspire labourers to play out their assignments in
more effective manner. Pakistan railway internship should be stipend

86
Chapter 6 References
http://pu.edu.pk/images/journal/studies/
http://www.railways.gov.pk/
https://themechanicalengineering.com/
https://learnmechanical.com/
https://www.pakrail.gov.pk/images/pmu/mech_code_wkps.pdf http://www.railcop-
pk.com/introduction.htm https://en.wikipedia.org/wiki/Pakistan_Railways
https://www.thenews.com.pk/print/434106-a-visit-to-the-workshop-that-keeps- pakistan-
railways-locomotives-chugging
https://www.researchgate.net/publication/262011817_History_of_Pakistan_Rail way

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