2 university haider report.pdf Supervised Industrial Training

INDUSTRIAL TRAINING REPORT Page 1
PUNJAB TIANJIN
UNIVERSITY OF
TECHNOLOGY
PAKISTAN
RAILWAY
MUGHALPURA
INDUSTRIAL TRAINING REPORT
Name HAIDER ALI
Roll No 19AU041
DEPARTMENT AUTOMOTIVE ENGINEERING TECHNOLOGY
Industrial Training Course Supervised Industrial Training
Training Period 27-03-2023 to 22-07-2023 (16 WEEKS)
Training Organization Pakistan Railways Mugalpura

ABSTRACT
The internships in companies are an important part of the students schooling at the
graduate level. Students have to do internships in the company of their choice at the end
of their final year in order to get experience in a professional context. For the last four
months, I have done my final year internship in Pakistan Railways (Mugalpura
Workshops). The main subject of my work is the application of technical skills and
ingenuity to correctequipment problems causing equipment downtime and maintenance
work. Dedication to the maintenance function and is focused on the elimination of
repetitive failures. Ensuring the maintain ability of new installations. Identifying and
correcting chronic andcostly equipment problems, eliminate repetitive failures.
Inspection, adjustments, parts, replacements, overhauls, etc., for selected equipment.
I think this internship is a great experience for my future. In order to explain this, I will
talk about internships in general, and then make the point with my professional project.
In my opinion, internships are one of the most important things in the engineer schooling.
Indeed, they contain a lot of things the student engineer will need to start in his career;
for example, taking contact with companies, writing cover letters, visualizing
management skills, and going through interviews. But most of all, it helps me to get use
to the railway environment, to interact with its different actors. Plus, it makes me to
evaluate my theoretical knowledge into practical work and it develops a certain kind of
autonomy. Globally, I would say that an Internship develop my capacity to adapt and
complete the courses I follow at the educational institutes Professionally speaking, this
internship has reinforced my interest for a work placement in Production Department asI
feel that it would suit better my professional expectations. I am pleased with what I have
done here, and what I have liked the most is the possibility to go through with whatyou
are working and to have the necessary time to carry things out.

ACKNOWLEDGEMENT
My name is Haider Ali student of automotive engineering technology in Punjab
Tianjin University of Technology, Lahore. First of all, I am extremely grateful to Allah,
the Almighty, who has given me the opportunity to complete this work. Next, I am
thankful to Pakistan Railway Department (especially MET) for giving me the
opportunity to do internship there. It gives me great pleasure to pay tribute to all the staff
members working in the Railway Department for showing their enthusiasm and passion
towards their area of work. His support in guiding me on the technical aspects of the
work done in the workshops is appreciated.
It helped me significantly in completing my report. This training would not have
been possible if the coordinator Ghilman Haider had not given permission earlier. So,
thanks for that too.
Also I am very grateful to Foreman Rehabilitation Shop; Foreman Diesel classified
and repairs Shop, Foreman E&DC Shop, Foreman Tool Shop, Foreman Foundry Shop,
Foreman power plant Shop, Foreman heat treatment Shop, Foreman roller bearing Shop,
Foreman motor Shop and Foreman of central laboratory MGPR. The respective in-
charge men and sub-engineers guide me and my colleagues very well in every matter.
I express my sincere thanks to the Senior Section Engineer who helped me through
his expert guidance during this training. Had it not been for his encouragement and
motivation, I would not have seen an honest course of success through this training
course.

Table of Contents
ABSTRACT......................................................................................................................2
ACKNOWLEDGEMENT...............................................................................................3
Chapter 1 ........................................................................................................................11
Backgrounds of the Pakistan Railway..........................................................................11
VISION & MISSION...................................................................................................12
Vision........................................................................................................................12
Mission .....................................................................................................................12
Organogram of Mughalpura Railway ..........................................................................13
Railway Board..............................................................................................................14
Design office ................................................................................................................15
Divisions.......................................................................................................................17
Major Departments.......................................................................................................17
Factory Area.................................................................................................................17
Chapter 2 ........................................................................................................................18
Schedule of Training ....................................................................................................18
Duties as a Trainee .......................................................................................................20
Workshops Graph of Pakistan Railway in Mughalpura in which I go.........................20
Chapter 3 ........................................................................................................................21
Working Experience.....................................................................................................21
Daily Training Activities..............................................................................................22
Chapter 4 ........................................................................................................................30
Project Carried Out.......................................................................................................30
DIESEL CLASSIFIED REPAIR SHOP......................................................................30
Project carried out in Diesel Classified Shop...............................................................30
Dismantling of Locomotive......................................................................................30
Locomotive and Diesel Engine Parts........................................................................31
Bogie assembly section.............................................................................................31
Wheel Assembly project...........................................................................................32
Hand on skills in Diesel Shop ......................................................................................33
Traction Motor Testing.............................................................................................33

Problems facing............................................................................................................34
Problems Solving .........................................................................................................34
Supervisory works in Diesel Classified Shop ..............................................................35
Yearly outturn table ..................................................................................................35
How the productivity can be further enhanced in diesel shop .....................................36
Quality management ....................................................................................................36
Safety at work...............................................................................................................37
Working Experience in Diesel Classified Shop Loco shop .........................................37
E & DC SHOP................................................................................................................38
Project Carried Out in E & DC SHOP .........................................................................38
Lathe machines .........................................................................................................38
Milling Section .........................................................................................................38
Grinding Machines ...................................................................................................39
Fitting Section...........................................................................................................40
Hand on Skills in E&DC Shop.....................................................................................40
Supervisory works in E&DC Shop ..............................................................................40
How Productivity can enhanced in a E & DC shop .....................................................41
Quality Management system........................................................................................41
Safety at Work..............................................................................................................42
Working Experience in E & DC SHOP Loco shop .....................................................42
TOOL SHOP ..................................................................................................................43
Project Carried Out in Tool Shop.................................................................................43
Milling Section .........................................................................................................43
Lathe Section ............................................................................................................43
Grinding Section.......................................................................................................44
Fitting Section...........................................................................................................44
Die Section................................................................................................................45
Hand on Skills in Tool Shop ........................................................................................45
Supervisory works in Tool Shop..................................................................................46
How Productivity can enhanced in a tool system ........................................................46
Quality Management system........................................................................................47

Safety at Work..............................................................................................................47
Working Experience in TOOL SHOP Loco shop........................................................47
DIESEL REHABILITATION SHOP ..........................................................................48
Project carried out in Diesel Rehabilitation shop.........................................................48
Rehabilitation Maintenance Loco Engines...............................................................48
Preventive Maintenance of the PR Locomotives......................................................48
Steam and Diesel Locomotives ................................................................................48
Schedule maintenance of Rehabilitation Shop .........................................................49
Electric Locomotives................................................................................................50
Rolling Stocks...........................................................................................................51
Hand on Skills in Rehabilitation Shop.........................................................................52
Pre-Inspection...........................................................................................................52
Problems Encountered..............................................................................................53
Problems Solving......................................................................................................53
Supervisory Work in the Rehabilitation Shop..............................................................53
Disassemble Section.................................................................................................54
Bogie of Locomotive................................................................................................54
Main Component of bogie is following....................................................................55
Central Pivot.............................................................................................................55
Traction Motor..........................................................................................................56
How Productivity can enhanced in a given system......................................................56
Quality Management....................................................................................................56
Safety at Work..............................................................................................................57
Working Experience in Rehabilitation shop Loco shop...............................................57
FOUNDRY SHOP..........................................................................................................58
Project Carried Out in Foundry Shop...........................................................................58
Parts prepared in brass foundry ................................................................................58
Mould Preparation ....................................................................................................59
Hand on skills in Foundry Shop...................................................................................60
Problems Encountered..................................................................................................60

Supervisory Work in the Rehabilitation Shop..............................................................61
CASTING.................................................................................................................61
Safety at Work..............................................................................................................62
Work Experience in foundry shop ...............................................................................62
POWER PLANT SHOP................................................................................................63
Project carried out Power plant shop............................................................................63
Diesel Generator .......................................................................................................64
Hand on skills in Power Plant Shop.............................................................................65
Supervisory Work in the power plant Shop .................................................................66
Types of power van used in Pakistan railway ..........................................................66
CHINESE POWER VAN.........................................................................................66
GERMAN POWER VAN ........................................................................................67
T-L type power van ..................................................................................................67
Safety at Work..............................................................................................................69
Work Experience in Power Plant shop C&W shop......................................................69
HEAT TREATMENT SHOP........................................................................................70
Project Carried Out in Heat Treatment Shop ...............................................................70
Screw coupling process ............................................................................................71
Supervisory Work in the heat treatment Shop .............................................................72
Types of Heat Treatment Processes..........................................................................72
Types of Heat Treatment ..........................................................................................72
Carburising ...............................................................................................................74
Purpose of Heat Treatment of Steel..........................................................................74

Safety at Work..............................................................................................................75
Work Experience in heat treatment shop C&W shop ..................................................75
ROLLER BEARING SHOP .........................................................................................76
Project carried out in Roller Bearing shop ...................................................................76
Removal of bearing from wheel...................................................................................76
Supervisory Work in the heat treatment Shop .............................................................77
Cylindrical roller bearings........................................................................................77
Spherical roller bearings...........................................................................................78
Needle roller bearings...............................................................................................78
Locking system for roller bearing end cap ...............................................................79
Safety at Work..............................................................................................................80
Work Experience in Roller Bearing shop C&W shop .................................................80
MOTOR SHOP ..............................................................................................................81
Project carried out in motor shop .................................................................................81
Diesel Engine Overhauled........................................................................................81
Mazda index..............................................................................................................82
Supervisory Work in the motor Shop...........................................................................83
Difference b/w diesel and patrol engine ...................................................................83
Safety at Work..............................................................................................................85
Work Experience in Motor shop C&W shop...............................................................85
CENTRAL LABORATORY MGPR ...........................................................................86
Central laboratory section graph ..................................................................................87
Sample Collection and Testing ....................................................................................88
Quality Control Analysis..............................................................................................88
Chemical Analysis........................................................................................................88

Material Testing ...........................................................................................................88
Environmental Monitoring...........................................................................................89
Steel shop .....................................................................................................................89
Purpose of Steel Shop ..................................................................................................89
Spectrometer.................................................................................................................90
How Does a Spectrometer Work..............................................................................90
The Components within a Spectrometer ..................................................................90
Spectrometers from Admesy ....................................................................................91
Chapter 5 ........................................................................................................................93
Conclusion....................................................................................................................93
Recommendations ........................................................................................................94
Chapter 6 ........................................................................................................................95
References ....................................................................................................................95
Appendix ......................................................................................................................96

Table of Figure
Figure 1: North Western State Railway (The Eagle).......................................................11
Figure 2: Training later ....................................................................................................19
Figure 3: Disassembled train engine................................................................................30
Figure 4: Bogie ................................................................................................................31
Figure 5: Wheel Assembly machine................................................................................32
Figure 6: Yearly outturn table..........................................................................................35
Figure 7: Lathe machine ..................................................................................................38
Figure 8: Milling Section.................................................................................................39
Figure 9: Grinding of Crank Shaft...................................................................................39
Figure 10: Milling............................................................................................................43
Figure 11: Lathe Section..................................................................................................44
Figure 12: Grinding machine...........................................................................................44
Figure 13: Fitting tools.....................................................................................................45
Figure 14: Die section......................................................................................................45
Figure 15: Rehabilitation shop.........................................................................................53
Figure 16: Prepared Parts.................................................................................................58
Figure 17: Aluminum Furness .........................................................................................59
Figure 18: Furness............................................................................................................59
Figure 19: CASTING.......................................................................................................61
Figure 20: power van .......................................................................................................63
Figure 21: Cummins diesel generator..............................................................................64
Figure 22: HEAT TREATMENT process .......................................................................70
Figure 23: Screw coupling process ..................................................................................71
Figure 24: Betex BPP Puller Pusher, used for installation and removal of railway bearing
sets....................................................................................................................................76
Figure 25: Cylindrical roller bearing ...............................................................................77
Figure 26: Spherical roller bearing ..................................................................................78
Figure 27: Needle roller bearings ....................................................................................78
Figure 28: Locking system for roller bearing end cap.....................................................79
Figure 29: DIESEL ENGINE OVERHAULED..............................................................81
Figure 30: Central Laboratory..........................................................................................86
Figure 31: Spectrometer...................................................................................................90

Chapter 1
Backgrounds of the Pakistan Railway
After the partition of British India and the independence of Pakistan in 1947,
Northwestern State Railway had most of its infrastructure in Pakistani territory and was
renamed Pakistan Western Railway. In East Bengal, the section of the Assam Bengal
Railway in Pakistani territory was renamed the Pakistan Eastern Railway. The country
adopted 8,122 km (5,047 mi) of the North Western State Railway; 6,880 km (4,280 mi)
was 1,676 mm (5 ft 6 in), 506 km (314 mi) 1,000 mm (3 ft 3+3⁄8 in) meter gauge, and
736 km (457 mi) (762 mi) ft 6 in) narrow gauge.
In 1954, a branch line was extended from the Karachi-Peshawar railway line to
Mardan and Charsada. Two years later, the Jacobabad-Kashmore meter gauge line was
changed to 1,676 mm (5 ft 6 in) broad gauge. The Kot Addu-Kashmore section of the
Kotri-Attock railway line was built from 1969 to 1973, providing an alternative route
from Karachi to North Pakistan. In 1974, the name of Pakistan Western Railway was
changed to Pakistan Railway. In February 2006, the 126-km (78 mi) Hyderabad–
Khokhrapar branch line was converted to 1,676 mm (5 ft 6 in). During the 2000s, all
Figure 1: North Western State Railway (The Eagle)

narrow gauge tracks in the country were changed to 1,676 mm (5 ft 6 in) or scrapped.
On 8 January 2016, the Lodhran-Raiwind Branch Line Double Rail project was
completed.
VISION & MISSION
Vision
To achieve excellence in engineering services with special emphasis on the railway
sector and to be an international trading company operating beyond the borders of
Pakistan.
Mission
Mission is leading the public and private sector in engineering fields including
railways. Providing the highest quality and safety standards in an economical and
efficient manner.

Organogram of Mughalpura Railway
D.S/W
Dy D.S/W
DPO/W
MET/W WM/C
DEN/W WM/M
WM/Steel WM/Const
onst
WM/Loco PEM/W
DEE/W DMO/W
DEE/P SRP/W
WM/HDR CC&M
MS/W
DAO/W

Railway Board
The Railway Board functioned from 1959 to 2000 and was amended between 2000
and 2014 with the addition of the "Executive Committee of the Railway Board".
However, on 20 February 2015, the Railway Board was reconstituted. Chairman
Pakistan Railway Board Independent Board consists of:
1. Secretary (Minister of Railways)
2. Secretary, Communications Division
3. Secretary, Finance Division
4. Secretary, Planning & Development Division
5. General Manager (Operations)
6. General Manager (Manufacturing & Services)
This composition could not be approved by the Parliament and at present the
members of the Board are ex-officio. The Secretary is also the Chairman of the Railway
Board. The Secretariat of the Board is headed by the Secretary Railway Board. The seat
of the Board is Ministry of Railways, Islamabad
Manister of railway
Secretary
Chairman
Railway (BS-22)
Secretary railway
Board (BS-21)
Director Estt
(BS-19)
Director Admin
(BS-19)
Direc villages
(BS-19)
DG Operations
(BS-20)
Member Finance
(BS-21)
Dir/F&B
(BS-19)
DG Technical
(BS-20)
DG Planning
(BS-20)

Design office
The success of any transportation project depends on its construction. With well-
thought-out and well-designed stations, cars and other components of a public transport
network, an effective design can attract more users. On all railways, the Design Office
provides the following services:
1. Track design (alignment, positioning, blank line and shift and crossing, gauge
specification) Signal and train control design (scheme development, building
design)
2. Construction of a communication system.
3. Top centenary design.
4. Mechanical and Electrical Design.
5. Channel design.
6. Community design and structure.
7. Internal and external parts design.
The design and painting office is equipped with the latest technology and can
design and arrange any type of stock. During project execution, the design office
provides support to the production department, and any issues are resolved by qualified
design professionals. This office also has a library.

There are currently two types of coaches available in Pakistan:
 German coaches.
 Chinese coaches.
Maximum trainers/Dimensions of coaches:
The size of the Railway in Pakistan is measured in mm.
1. Trainer length = 22606mm
2. Coach width = 3251mm
3. Coach height = 2899mm
There are some coaches who are designed for a specific purpose.
Power Van: Designed to carry an engine to power appliances and air conditioners.
Luggage Van: Used to carry passengers' luggage
Restaurant: It is like a train traveling for a long-distance train.
Wedding car: Specially designed for long-distance weddings.

Divisions
Pakistan Railway comprises seven territorial operating divisions:
Karachi Lahore
Multan Peshawar
Quetta Rawalpindi
Sukkur
Major Departments
Mechanical department Electrical department
Store department Civil engineering department
Factory Area
Covered area 27 acres
Uncovered 165 acres
Factory Area 192 acres

Chapter 2
Schedule of Training
In this chapter, I will look at the details of the workshops and workshops as well as
the training program in the areas where I spent four months of training (16 weeks).
There were several places in the train interviews where I completed my training days
and did various jobs and activities related to the workshop environment.
The role and training program are explained in more detail below. I completed my
8 hours of exercise five days a week as per NTC requirements. Check-in and check-out
times for the workshop are 8:00 am and 4:00 pm respectively. A 2-hour lunch break is
available. There are other job sites where I completed my training which are listed
below:
 In my 16 week schedule of industrials training, I am directed to visit nine
workshops and one Laboratory. Five workshops from Locomotives and four
from C&W shops and last one is central laboratory.
The schedule of my training is given below:
Name HAIDER ALI
Roll No 19AU041
Department AUTOMOTIVE
Organization PAKISTAN RAILWAY

Figure 2: Training later

Duties as a Trainee
As a trainee, I have to observe all the working processes at different sites or work
places. My duties are to analyze common faults and their solutions including time
management and other important factors that affect the maintenance process of any
working site.
These factors are the following:
1. To understand the manufacturing and repairing of rail coaches and wagons.
2. To observe and acquire knowledge about different mechanisms dealing with
different machines.
3. To apply the theoretical technical knowledge to real industrial applications.
4. To build good communication skills with a group of workers and learn
properbehavior of corporate life in the industrial sector.
5. To enhance the ability to improve students’ creativity skills and share ideas.
Workshops Graph of Pakistan Railway in Mughalpura in which I go
Locomotive workshops Carriage and Wagon
Shop
Laboratories (for
testing of materials)
Diesel Classified and Repair
Shop
Power Plant Shop Central Laboratory
MGPR
E&DC Shop Heat Treatment Shop
Tool Shop Roller Baring Shop
Diesel Rehabilitation Shop Motor Shop
Foundry Shop

Chapter 3
Working Experience
In this chapter, I discuss key learning outcomes from this training as well as other
key components and resources identified in Pakistan Railways workshops across the
country. Many types of manufacturing, production, processing and special purpose
equipment are used in all forums. Everyone knows that all machines work with some
form of energy. Electric power is suitable for control, conversion, and various other
functions.
Therefore, I used machine tools and equipment for all my manufacturing
equipment, processing, and other purposes. As a result, I found useful tools at various
workplaces. The following sections of this chapter provide a detailed discussion of
several related components and tools identified in the workshops.
I participated in workshops, which are listed here, and information about the work
and other related resources for these discussions and venues. The following paragraphs
include a detailed workshop and a quick description of my work in this workspace.
I also work in the central laboratory where I see how to check the materials with the
help of chemical or physical methods and also work on the latest testing machine
spectrometer. I also work on the mechanical testing machines there.

Daily Training Activities
Training Week 1
I visited Apprentice College to get our schedule
I went to Diesel Classified shop and submitted our
training letter. Get Attendance from the clerk. Then I
have a introduce with Foreman and workers
I visited shop and charge man gave us brief
introduction about the components of shop.
I went to duty point of Engine Overhaul shop and
visited the Site
I stayed at duty point and checked the repairing
Work.
Study about different torque value of body truck parts
Training Week 2
I went to shop and worker gave the information about
the overhauled components
I inspected various tool used in the workshop
I inspected the various components of engine
I worked with the workers and reassemble the engine
parts
I checked that how turbocharger is installed in the
engine
I helped workers in changing the main gas kit of
Diesel engine.

Training Week 3
I helped workers in changing the main gas kit of
Diesel engine.
I listed the cylinder firing order and the working of
rocker arm and camshaft
I inspected the nozzles and crank case under the
supervision of foreman
I inspected the Water pump and air compressor and
gained knowledge from the foreman
He told us about the purpose of this workshop and the
tools used in the workshop
We compiled our attendance sheet by signing it
from foreman and submitted to clerk office in Diesel
classified shop
Training Week 4
I went to E & DC shop and submitted my
Schedule. And foreman gave the introduction about this
shop.
I understood that which machine is used in different
shop sections. I checked the different operation like
facing, turning process.
I inspected different workpiece prepared in the shop. In
grinding section, I observed different operations done on
the grinding machine.
I compiled my attendance sheet by signing it from
foreman and submitted to clerk office in E & DC shop.

Training Week 5
I went to Tool shop and submitted my
Schedule. And foreman gave the introduction about
this shop
I observed the different operations performed in the
lathe machine operations
I observed the different operations performed in the
fitting machine section
foreman and submitted to clerk office.
Training Week 6
I went to Rehabilitation shop and submitted my
this shop
Visual Inspection of crank shaft and balancing of crank
shaft
Visual inspection of batteries and their rack in fuel
tank
Visual study of accidental locomotive.
Study of brake locomotive and their working
procedure

Training Week 8
foreman and submitted to clerk office in rehabilitation
shop.
I went to foundry shop and submitted my
this shop
Visual inspection of furnace and melting of iron.
Visual inspection of furnaces used in this shop.
I learned how to made sand mixture for casting
I learned how to make brakes and door handle and AC
vents from molten metal.
Training Week 7
Visual inspection of engine and train body.
Visual inspection of damage of bogie.
Visual inspection of Solving procedure.
Study of locomotive beam and types used in advance
locomotive.
Visual study separating accidental locomotive and its
rehabilitation.
Visual study of basic operation of locomotive.

Training Week 9
Visual inspection of copper furnace and their material
made.
I studied melting temperature of different materials.
I checked the hardness of material that made in this
shop.
foreman and submitted to clerk office in Foundry shop.
I went to Power plant shop and submitted my
this shop
Inspection of Cummins generator used in power van.
Training Week 10
I observed about the control system and circuit
diagram of generator.
Observe and inspect the control panel and their
function.
Study about the project workflow in power plant shop.
I checked the voltage output of generator.
I learnt about the disassembling and overhauling of
diesel generator.
I learnt about the assembling of the diesel generator.

Training Week 11
Inspection of coupler connection in power van.
Learned the working principle of coupler.
Inspection of wiring in power van.
I learned the difference between Chinese and German
power van.
I learned the safety factor of power plant shop.
foreman and submitted to clerk office in Power plant
shop.
Training Week 12
I went to Heat treatment shop and submitted my
this shop.
Inspection of different furnaces used in this shop.
I learned about the shop projects workflow.
Inspect the hardness of different materials.
I learned the safety factor of heat treatment shop.
foreman and submitted to clerk office in Heat
treatment shop.

Training Week 13
I went to Roller Bearing shop and submitted my
this shop.
I learned about the disassembling of different types of
bearing from wheel.
I gained knowledge about different types of bearing
used in this Bogie.
Learned about puller and pusher machine.
I learned about the servicing of different bearings.
I learned about the repairing process of bearing.
Training Week14
I learned the safety factor of roller bearing shop.
foreman and submitted to clerk office in roller bearing
shop.
Training Week 15
I went to motor shop and submitted my
this shop.
I learned about the repairing section of vehicle used in
Pakistan railway.
I learned the basic difference between petrol and diesel
engine.
I learned how to check radiator and also know how to
visually inspection of diesel buses.
I learned how to disassemble the diesel engine for over
hauling.
I learned the sign of diesel engine may be weak or
need to be over hauled.

Training Week 17
In this shop, I inspected the electrical and brake system
I learned the safety factor of motor shop.
foreman and submitted to clerk office in motor shop.
I went to central laboratory MGPR and submitted my
this lab.
I learned about the material testing method and
inspecting the projects of steel section and testing
method of oil and fuel used in Pakistan railway.
I learned the safety factor central lab. I compiled my
attendance sheet by signing it from foreman and
submitted to clerk office in central lab.
Training Week 16
I learned how to adjust piston rings in diesel engine.
I learned how to adjust the timing of diesel engine.
I gained information of how to assemble the diesel
engine after over hauling.
I got information that how to inspect the diesel engine
after over hauling.
I learned the basic maintenance of diesel engine.
I inspected the suspension of buses in motor shop.

Chapter 4
Project Carried Out
DIESEL CLASSIFIED REPAIR SHOP
Project carried out in Diesel Classified Shop
Dismantling of Locomotive
After handing over the locomotive, first,
the nut bolts connecting the body and the
trucks are loosened. Then the body of the
locomotive is raised and then the bogies are
separated. The trucks are lifted by lifting the
engine body over the stand. The motor is
removed from the wheels and sent to the
rewinding shop for overhauling the motors.
The engine wheels were removed and sent to the wheel shop for machining and
inspection.
Diesel Classified Workshop is responsible for overhauling of all locomotives of
Pakistan Railways every 5 years. 5 different segments are working for diesel
classification.
1. Power assembly section.
2. Nozzle, fuel Injection & pump section.
3. Governor section.
Figure 3: Disassembled train engine

4. Electrical section.
5. Air compression section.
6. Bogie assembly section
7. Turbo supercharger section.
Locomotive and Diesel Engine Parts
1. Wheel for Locomotives.
2. Pistons.
3. Piston Connection Rod.
4. Piston Assembly.
5. Piston Ring.
6. Engine Bearing.
7. Crankshaft.
8. Exhaust Valve.
9. Engine Gears
10. Fuel Injectors
Bogie assembly section
The loco is provided with a forged
bogie. It is a three-axle, two-stage
suspension with helical coil springs in the
primary stage and rubber compression
springs in the secondary stage of suspension
and a floating-type center pivot
arrangement. The bogie frame shall be of
box type construction fabricated from steel plate to IS.2062 grade 'C'.
Figure 4: Bogie

The body weight of the locomotive car is transferred directly to the bogie frame by
means of four rubber "compression" spring assemblies. The bogie frame is supported by
a "soft primary" suspension consisting of eight pairs of helical coil springs (inner and
outer). Two springs are mounted on each axle to provide equalization of ride quality and
wheel seat load.
Wheel Assembly project
This is the part of the rack that is
closest to the tracks. It consists of four
main parts:
1. The wheel
2. Axle
3. Bearing and housing
Wheel and axle components
1. Two brake discs (4), diameter 640 mm and
2. Width 110 mm.
3. Inbuilt slack adjusting brake cylinder installed.
4. Two wheel disc diameter 915 (new), 845 (worn).
Figure 5: Wheel Assembly machine

Hand on skills in Diesel Shop
Traction Motor Testing
During this test I can get the following indicators for different measurement tests
and different test results:
1. I wheel bubbling test with its help.
2. Grease or oil leakage.
3. I check the temperature of traction motor during testing with the help of
temperature meter.
4. Temp test (ambient temperature should rise by 20+). If the temperature is 20, that
means add 10 to 20 = 30.
5. I check the noise test during this process.
6. I achieve 450 rpm in this motor during testing.
After one year of motor working the motor is dry then I repair it after 1 year.
Note: The maximum voltage during this entire test is 130.
Note: The maximum amperage during this entire procedure is 80.
Note: Throughout this process. This motor uses a hold type chemical to hold the threads
of the nut.

Problems facing
While working at diesel shop I face many problems:
1. Do not overuse silicon during traction motor testing with internal traction motor
problems.
2. Center Pivot Not Welded Properly If it is not properly welded and finished
properly, it is not properly fitted in its position and if it is not in its position If it
does not fit then the train cannot move the specified and proper required amount
of degree 60 as its transfer aids. Trains left or right.
3. Not using the mega meter correctly.
Problems Solving
Use the required amount of silicon during testing according to manufacturing
specifications.
1. Proper welding and finishing of center pivots.
2. Use the mega meter correctly (adjust the difference before using the meter which is
zero).

Supervisory works in Diesel Classified Shop
I am working in this shop under the supervision of Sir Zahid who is the in-charge in
Diesel Classified Workshops. They guide me through my internship period which I
spend in diesel shop:
1. Imagine an inspection of diesel engines.
2. Overhauling of locomotives.
3. Testing and Inspection of Diesel Engine Parts.
4. Dismantling the engines.
5. Testing the traction motor.
Yearly outturn table
Figure 6: Yearly outturn table

How the productivity can be further enhanced in diesel shop
The workshop of Pakistan Railways is a very practical institution. The best and
most profitable thing is that the workshop is completely free. It requires no external
vendors or manufacturing capabilities. This part is very powerful for railway workshop.
The main objective of a railway workshop is to maintain the locomotives, to carry out
their routine maintenance. The organization is doing its work very well but with old
techniques. Some tips are suggested to increase productivity:
1. Using modern equipment and techniques. For example that in the engine
block shop
2. Still using the old telescope for scoping and alignment. Using modern laser
and graphical techniques can save both time and money.
3. Time management and team coordination is very important in every field.
The railway system is good but needs some improvement to increase their
productivity and creativity.
4. 4. Production shops like forging, blacksmith, spring and casting shop. Can be
used to make external projects and parts. This can increase their profits and
popularity.
Quality management
1. The quality management system of Pakistan Railway Workshop is very good.
The workshop is ISO 9001:2008, which means the work is fully
standardized.
2. They are using old techniques but working with absolute quality. They have a
proper inspection and testing system. It can be further enhanced by using
modern techniques

Safety at work
1. In this shop they have sunglasses for workers to protect eyes from metal
chips during welding or finishing.
2. There is a fire extinguisher and no emergency exit in the diesel shop.
3. Workers are working with protective shoes and gloves.
4. Many other points which can also cause damage to persons and property.
Safety at work is very important.
Working Experience in Diesel Classified Shop Loco shop
My work experience I supervised various parts of repair and testing in diesel
classification shop. I test traction motor load testing. First, they fill the bogie wheel and
its fitting case with high quality grease. And then they run the motor at different loads
and speeds for a specified period of time to check for vibration or any leakage.

E & DC SHOP
Project Carried Out in E & DC SHOP
Lathe machines
A lathe is a machine tool used primarily for shaping metal objects (and sometimes
wood or other materials) by holding and rotating the workpiece through a lathe while a
tool bit is inserted into the work. is pushed forward causing cutting action. The basic
lathe that was designed to cut cylindrical metal stock has been further developed to
produce screw threads. Tapered work, drilled holes, knurled surfaces and crankshafts
work are done with this machine.
Milling Section
Milling is a machining process that uses a rotary cutter to remove material from a
workpiece by advancing (or feeding) in one direction at an angle to the axis of the tool.
It covers a wide variety of operations and machines, from small individual parts to large,
Figure 7: Lathe machine

heavy-duty gang milling operations. It is one of the most widely used processes in
industry and machine shops today for manufacturing parts to precise sizes and shapes.
Grinding Machines
Grinding machines are also considered machine tools. A distinguishing feature of
grinding machines is the rotating scraper. A grinding machine is used to achieve high
precision with a very high degree of surface finish on the workpiece.
A grinder, often shortened to grinder, is any of a variety of power tools or machine
tools used for grinding, a type of machining that uses an abrasive wheel as a cutting tool.
Uses Each abrasive grain on the surface of the wheel cuts a small chip from the
workpiece through shear deformation. Grinding is used to finish a workpiece that
exhibits high surface quality (eg, low surface roughness) and high accuracy of shape and
dimensions.
Figure 8: Milling Section
Figure 9: Grinding of Crank Shaft

Fitting Section
Working on components with hand tools and equipment, mostly on workbenches, is
commonly referred to as 'fitting work'. Hand operations in a fitting shop include
marking, filing, sawing, scraping, drilling, tapping, grinding, etc by using hand tools or
power-operated portable tools.
Hand on Skills in E&DC Shop
 Working on lathe machine where I made friction plate.
 Working on grinding machine that grind up the surface.
 Working on lath machine that makes tool for making objects
 Working in fitting section where I learn fitting of parts.
Supervisory works in E&DC Shop
I am working in this shop under the supervision of Sir Ali who is the in-charge in
E&DC Workshops. They guide me through my internship period which I spend in
E&DC shop:
1. Check how they make friction plate of engine.
2. Making shell bearing of engine.
3. Testing and Inspection of Diesel Engine Parts.
4. I saw how the crank shaft is to be made.
5. Testing engine different parts.

How Productivity can enhanced in a E & DC shop
Workshop of Pakistan Railways is a very useful institution. One of the best and
most profitable things is that the workshop is completely free. It does not require an
external vendor or product. This section is filled with the power of the Railway
Workshop. The main motivation of a train workshop is to maintain the train, to maintain
it from time to time. The organization does its work very well but in a very old
fashioned way. In the process of increasing productivity, some points are raised:
1. Time management and team communication are very important in all fields.
2. The workplace also has a lot of working and production space. Manufacturing
stores like forging, blacksmith, spring and casting shop. It can be used for
external projects and components. This can increase their profits and popularity.
Quality Management system
The quality management system of Pakistan Railway Workshop is excellent. The
workshop is ISO 9001:2008, which means the performance is absolutely standard.

Safety at Work
Pakistan Railway Workshop is following any OSHA rules and other safety procedures.
1. In E & DC shop they have sunglasses for workers to protect eyes from metal
chips.
2. E&DC shop has fire extinguisher and no emergency exit.
3. Workers are working with safety shoes and gloves.
4. They are wearing proper cloth.
Working Experience in E & DC SHOP Loco shop
A number of fabrication and manufacturing machines are installed and working in
the E&DC shop on the preparation of different parts of engine and other component
which are used for machining and fabrication of other related railway and train engine
and equipment in other sections and shops. I saw him working with sir imran, and he
was making different parts of engine that are used in engine.

TOOL SHOP
Project Carried Out in Tool Shop
Milling Section
A milling machine removes material from a workpiece by rotating a cutting tool
(cutter) and moving it into the workpiece. Milling machines, either vertical or horizontal,
are typically used to machine flat and irregularly shaped surfaces and can be used to
drill, bore and cut gears, threads and slots.
Lathe Section
The term lathe machine is referred to as the "mother of machining tools", lathes can
be used for a variety of purposes. These include shaping, drilling, sanding, curving,
bending, cutting, and deformation. It's hard to beat that kind of versatility in a tool, and
it's why many metal and woodworkers rely on lathes for their work.
Figure 10: Milling

Grinding Section
Tool grinding is a subset of the larger field of grinding. It involves a machining-
based production process in which a workpiece is prepared or re-sharpened using
abrasive or grinding wheels.
Fitting Section
Fitting involves a certain amount of bench work using hand tools or power tools.
Various operations involved in fitting are filing, marking, sawing, chipping, drilling,
reaming, tapping etc.
Figure 11: Lathe Section
Figure 12: Grinding machine

Die Section
A die is a specialized tool that often uses a press to shape or cut materials for
components, parts, and machinery. These dies are usually custom made to meet the
exact specifications of whatever item they are making.
Hand on Skills in Tool Shop
 Working on die that cut pieces from metal plate.
 Working on milling machine that removes excessive material.
 Working on lath machine that makes tool for making bodies.
 Working in fitting section where I learn drilling and taping.
Figure 13: Fitting tools
Figure 14: Die section

Supervisory works in Tool Shop
I am working in this shop under the supervision of Sir Ahmad who is the in-charge
in Tool Workshops. They guide me through my internship period which I spend in Tool
shop:
1. Working on die.
2. Working on lathe machine to making tool.
3. Testing and Inspection of tools.
4. Working on milling that remove excessive material.
How Productivity can enhanced in a tool system
1. Time management and team communication are very important in all fields.
2. The workplace also has a lot of working and production space. Manufacturing

Quality Management system
Quality Management System of Pakistan Railway Workshop is excellent. The
workshop is ISO 9001:2008, which means the performance is absolutely standard.
Safety at Work
The Pakistan Railway workshop is not following any OSHA rules and other
safety procedures.
 In tool shop they are not sun glasses for workers to prevent the eyes from metal
chips.
 There is no fire extinguishers and emergency exit in the tool shop.
 Workers are working without safety shoes and gloves.
Working Experience in TOOL SHOP Loco shop
Several fabrication and manufacturing machines are installed and functioning in
the tool shop on themanufacture of tools that are utilized in other sections and shops
for machining and fabrication of other relevant railway and train equipment. I saw them
at work with zohaib, and they were constructing various tools for various uses. A
hardness machine was also used to assess the hardnessof manufactured bushes. If the
work piece is not sufficiently hard enough, it will be rejected and discarded.

DIESEL REHABILITATION SHOP
Project carried out in Diesel Rehabilitation shop
Rehabilitation Maintenance Loco Engines
Rehabilitation maintenance of loco engines has two major schedule types:
1. Preventation Maintenance.
2. Schedule shed Maintenance.
Preventive Maintenance of the PR Locomotives
The performance of trains depends on the reliability and availability of trains.
Proper and efficient train maintenance is the foundation of cost-effective train
operations. Maintenance procedures have emerged from the basic principle that all
assets must receive the necessary attention before they deteriorate due to aging and
become prone to failure. This is known as maintenance retention. Train block
maintenance can be broadly divided into two headings, namely periodic adjustments and
scheduled adjustments.
Steam and Diesel Locomotives
The life expectancy of steam and diesel trains is 40 and 36 years respectively. Due
to their long lifespan, it is important that both assets are properly and periodically stored
to ensure that their condition does not deteriorate. This is how steam and diesel trains are
maintained.

Schedule maintenance of Rehabilitation Shop
As part of preventive maintenance various test schedules have been developed to
give need-based attention to specific sections and parts of trains from time to time. The
inspection schedule lists all the different aspects that need to be taken into account
during the repair, depending on the aging and tear parts. The total number of kilometers
that should have been done these tests was also specified.
Steam locomotives following table outlines the various approved maintenance
schedules for steam locomotives based on the total distance in kilometers covered by the
locomotives. A diesel engine has a trip (or weekly) schedule, a fortnightly schedule, a
monthly schedule, a three-month schedule, a six-month schedule, an annual schedule, a
three-year schedule, and a six-year schedule (POH) designed for diesel locomotive.
Type of
schedule
km covered by
WP/WG
km covered by
YP/YG
Schedule I 1600 950-1100
Schedule II Every month ---
Schedule III 24,000 20,000
Schedule IV 48,000 40,000
These repair programs are based on experience and informed investigation into the
causes of train accidents. Compared to railway track, a diesel pump unit is much more
complex, often involving an indirect control system with many additional components.
As a result of this great complexity there is a great deal of inefficiencies upon the failure
of a particular component. Therefore, to ensure a high level of reliability, different
schedules for testing and maintenance have been developed. A 'service' of short
schedules, i.e. travel, bi-weekly, monthly, etc., which includes routine tests, small

attention and the like, takes about 4 to 12 hours. Larger schedules take longer, lasting
from 6 to 14 days, because they require major repairs and replacements.
Electric Locomotives
The schedules for inspection and checks given in following table are generally
followed on Pakistan Railways to ensure the proper maintenance of electric
locomotives.
Frequency Code Time period allotted
for completion
Nature of attention
Weekly/trip
(within 1500 km)
Trip 1 hr Weekly or trip
inspection
15 days Fortnightl
y
1 to 2 hrs Fortnight inspection
Monthly IA 2 hrs Incidental inspection
Two months IB 8 hrs Complete/partial
inspection
Four months IC 8 hrs Complete inspection
Every third
IC
AOH 16 hrs Annual inspection
At 300,000 km or
after 3 years
IDH 15 days General inspection or
intermediateoverhauling
At 600,000 km or
after 6 years
POH 30 days Through overhauling or
periodicaloverhauling

The frequency and duration of the various schedules have been determined after
considering the number of train failures, availability of indigenous components and air
and dust temperatures in the country. Compared to steam and diesel trains, electric trains
involve more contacts, relays, and instruments/equipment. Electrical values and changes
in locomotive state are not physically visible. Therefore, it is important to check the
devices, contacts and relays from time to time so that the condition of the various
devices can be ascertained without interruption. Most machines are tested during the
four-month test, so these devices are not included in the annual test. During such
inspections, equipment is disconnected from mechanical devices, assemblies are stripped
and cleaned, and broken or damaged parts are replaced and reassembled.
Travel to external work areas is reviewed either weekly or bi-weekly, and all other
schedule reviews with the exception of POH are conducted in the sheds. POH, however,
is practiced in workshops.
Rolling Stocks
Rolling stock includes locomotives, passenger coaches, goods wagons, and all other
types of coaches and wagons such as electric multiple units (EMUs), diesel railcars, and
special wagons such as BOX wagons. Some details of passenger coaches and goods
wagons are given in this section.

Hand on Skills in Rehabilitation Shop
Pre-Inspection
This is the inspection in which all pipe fittings, brake equipment are properly
installed and maintained before starting the following test.
 Test for pressure switch.
 Emergency application
 Reservoir charging.
 Full Break Request Issue a full break request.
 Sealing test
 Test for pressure switch.
 Device
 Issue an emergency brake request.
If there is any part is missing or is in damaged condition then it is reported on the
inspection form.

Problems Encountered
Following are the problems I face in this shop:
1. Not scheduling engines body properly.
2. Battery racks are not welded properly (where the batteries are mounted inside the
engines).
3. If it is not welded properly then the battery is not working properly or not fit.
4. Not having proper leveling of problem faced beams.
Problems Solving
 Maintenance of time schedule of engines body.
 Proper welded of battery rack.
 Proper leveling of I-beams under manufacturing practices.
Supervisory Work in the Rehabilitation Shop
My duties at repair shop are to see
locomotive engine repair tests and cart
frame and various other tests. All
replacement trains after accident and
train accident are done in repair shop.
I am working in this shop under the
supervision of Sir Manzoor who is CIR in
Figure 15: Rehabilitation shop

Locomotive Workshops. They guide me during my internship period that I spend in this
shop:
 Scheduling Process of Pakistan Railway Engines.
 Inspection and checking of I beams.
 Inspection and welding of Welded spots in engines.
 Inspection of Batteries use in Loco engines.
Two different sections are working for diesel classified Rehabilitation shop
 Assemble and Disassemble Section of Steam and Diesel Locomotives.
 Maintenance/Repair Section.
Disassemble Section
In the section, inspection of accident vehicle is to be done. The nuts and bolts that
connect the body and the truck are loosened and then the bogie and rail body are
separated and lifted by a crane. The lifting crane can bear 150 tons of white. Two crane
lifts lift the body together.
Bogie of Locomotive
The bogie plays an important role in connecting the rail body and the track for the
purpose of passenger safety and comfort. A bogie in technical terms is a chassis or
framework containing a wheel that is attached to a rail vehicle.

Bogies serve many purposes:
1. To support the body of the train.
2. Running consistently on both straight and curved paths.
3. To ensure rider comfort by absorbing vibrations and minimizing centrifugal
forces when the train runs at high speed on curved tracks.
4. Minimizing the generation of track irregularities and rail abrasion.
Main Component of bogie is following
 Bogie is frame itself.
 Brake components.
 Suspension to absorb shocks between bogie frame and rail body.
 Two Wheel set with axle at each end and one at the center.
 Traction motor.
Central Pivot
The central axis is located at the front of the frame to allow a certain degree of
rotation of the train. The pivot carries about 60% of the live load and receives and
transmits gravity and braking.
The axle's gut and loading area are greased for its line. The median axis is checked
for appearance. The central pivot pin connects the body to the bogie and transmits the
bogie's gravity and brakes. It has silent rubber trees that help keep the bogies in line with
the body and somewhat control and reduce the angular oscillations of the bogies.

Traction Motor
The traction motor is one of the main features of a diesel train, which plays a key
role in the smooth running of the train. The job of a locomotive engine is to convert
electrical energy into mechanical power around the wheels of the train. Transferring
equipment on a train is not recommended due to the size and weight of the train, gears
large enough to control it may be too large and too large to operate.
How Productivity can enhanced in a given system
Time management and team communication are very important in all fields. The
rail systems are good but need some upgrades to improve their production and crafting.
The workplace also has a lot of working and production space like manufacturing
stores like forging, blacksmith, spring and casting shop. It can be used for external
projects and components. This can increase their profits and popularity.
Quality Management
 The Quality Management System of Pakistan Railway Workshop is excellent.
The workshop is ISO 9001:2008, which means the performance is absolutely
standard.
 They use old techniques but they work perfectly. They have a proper system of
testing and evaluation. It can be further developed using modern techniques.

Safety at Work
Pakistan Railway Workshop is not following any OSHA rules and other safety
procedures.
 In this shop they do not have sunglasses for workers to protect eyes from metal
chips.
 Maintenance shop has no fire extinguisher and no emergency exit.
 Workers are working without safety shoes and gloves.
 Many points that can cause damage to persons and property. Safety at work is
very important.
Working Experience in Rehabilitation shop Loco shop
The main function of a Rehabilitation shop is to repair or restore damaged engines
so that they can be used again. I work with Mr. Manzoor, the foreman, who briefs me on
all the basic operations and parts of the rehabilitation shop. I also visit some accident
locomotives and study the traction motor and cooling system of a locomotive engine. I
see how they detach the engine axle from its bogie and use a 40-tonne horizontal pillar
crane to raise the locomotive body before resting it on ground-fixed jacks.

FOUNDRY SHOP
Project Carried Out in Foundry Shop
Parts prepared in brass foundry
 Sliding door handle.
 Upper birth handle.
 Coat hook.
 Window catcher.
 Window stopper.
 Window panel.
Figure 16: Prepared Parts

Mould Preparation
A mold is formed to the desired part geometry. The molten metal is then poured
into a mold, the mold holding the material in shape as it solidifies. A metal casting is
made. Although it sounds simple, the process of manufacturing metal castings is both a
science and an art. First, molds can be classified as open or closed. An open mold is a
container, like a cup, with only the desired part shape. The molten material is poured
directly into the mold cavity which is exposed to the open atmosphere.
Figure 18: Furness Figure 17: Aluminum Furness

Hand on skills in Foundry Shop
Below you will find the most important foundry worker skills. I ranked the top
foundry worker skills based on the percentage of foundry worker resumes on which they
appeared. For example, 35% of foundry workers' resumes include sand molding as a
skill.
 The most common occupation of foundry workers is sand molding. 35%
of foundry workers have this skill on their resume.
 The second most common hard skill for a foundry worker is aluminum
casting which appears on 9% of resumes. The third most common
foundry worker skill is arc welding at 7% of resumes.
 Three common foundry worker soft skills are computer skills, dexterity
and physical strength.
Following are the issues I faced in this shop:
1. Not scheduling the furnace properly.
2. Not filling mold properly.
3. The furnace does not work properly.
Problems Solving
1. In-time scheduling maintenance Furness.
2. Making sand properly for molding
3. Add salute in iron that makes it non sticky.

Supervisory Work in the Rehabilitation Shop
CASTING
Casting is a manufacturing
process in which a typically liquid
material is poured into a mold, which
has a hollow cavity of the desired
shape, and then allowed to solidify.
The solid part, also known as a
casting, is pulled or broken out of the
mold to complete the process. Casting materials are usually metals or different cold-
formed materials that solidify after two or more components are mixed together. Pouring
liquid metal into a previously made mold which confirms to the shape of desired
component.
The following are the basic operations of casting process:
1. Pattern making 2. Mold preparation 3. Melting the metal
 Time management and team communication are very important in all fields. The
rail systems are good but need some upgrades to improve their production and
Figure 19: CASTING

crafting.
 The workplace also has a lot of working and production space. Manufacturing
Quality Management
standard.
Safety at Work
The Pakistan Railway workshop is not following any OSHA rules and other safety
procedures.
 In this shop they do not protect their eyes from light of molten metal.
 There is no fire extinguishers and emergency exit in the foundry shop.
 All workers are not wearing proper clothes.
Work Experience in foundry shop
The main function of a foundry shop is to melt different type of material and from
molten metal they make things like brakes, window handles. I work with Mr. Naim, the
foreman, who briefs me about all the basic operations of the foundry shop and its
sections. I also see how materials melt in a furnace and types of furnace. The melting
temperature of different elements is aluminum melts at a temperature of 350-400°C.
Copper melts at 1100°C.

POWER PLANT SHOP
Project carried out Power plant shop
This shop overhauls and
repairs diesel engine pistons and
other mechanical parts used in
power vans. A power van is
basically a part of a train that
contains a generator and a
controlling system that supplies
electricity to the entire train for
use in the form of lighting, fans
or air-conditioners. There are two types of generators used in power vans. One is 300
KVA which is used in combination of two generators and 500 KVA which is used alone.
A generator is always kept in the power van as a backup generator in case of
emergencies or overloads. Fuel supply to these generators is taken by diesel tanks which
are kept in separate power vans for each generator and are called auxiliary tanks. A
power van usually holds two people for operation at a time during operation. A control
panel is used to control both generators during operation.
 Periodic Over Hauling POH.
 Complete repairing of carriage/ power van.
 NRM & NRE (Nominated Repair) Mechanical/Electrical.
Figure 20: power van

Diesel Generator
A diesel generator is a combination of a diesel engine with an electric generator (often
an alternator) to produce electrical energy. This is a specific case of engine-generator.
Diesel compression-ignition engines are often designed to run on fuel oil, but some
types are adapted for other liquid fuels or natural gases. It is supplied by diesel through
an auxiliary tank which is connected to the main tank and a motor is used to pump
diesel through the main tank to the auxiliary tank.
A 500 KVA diesel generator usually takes 30 liter/hour diesel in normal loads and
45 liter/hour in peak loads. The main tank can be from different ranges but mostly used a
3000-liter capacity tank. Trainload may vary from 3A to 55A, from normal to peak load.
In some cases, a generator of 75 KVA is also placed for extra load or if the load is very
less than 75 KVA generators is used.
Figure 21: Cummins diesel generator

Hand on skills in Power Plant Shop
During working in this shop my responsible is to work with the technician. I must have a
strong understanding of electrical systems and be able to troubleshoot problems. There
are 12 skills that every generator technician should possess:
 Improve my Electrical Systems Knowledge.
 How doing Generator Maintenance.
 Improve my Basic Welding.
 Improve my Basic Machining.
 Improve my Basic Fabrication.
 Improve my Basic Hydraulics.
 Improve my Basic Pneumatics.
 Improve my Basic Electronics.
 Improve my Basic Computer Skills.
 Improve my Strong Communication Skills.
 Improve my Strong Interpersonal Skills.
 Improve my Strong Problem-Solving Skills.
Following are the issues I faced in this shop:
 Generators overheat.
 Power output of generator is not smooth.
 Missing of generator.

Problems Solving
 Resolving issues of cooling system.
 By resolving issue of wiring.
 By Over haul generator.
Supervisory Work in the power plant Shop
Power van equipped with 2 digi set having capacity 350kVA (for AC or lights load).
Types of power van used in Pakistan railway
Two type of power van are used in PR
 Chinese
 German
CHINESE POWER VAN
DG makes Cummins capacity 350 kVA model KTA 1919-G2.
(K means the family of engine)
(T means engine having turbo)
(A means engine have after cooler)

(19 means displacement of engine in liters)
(G means engine have an alternator)
(02 is the class of engine)
1 DG set 75kVA make Perkins model 1104TG
GERMAN POWER VAN
Perkins Engines made in UK capacity 500kVA/ oblige 350kVA.
Engine model 2506C-E15TAG
(6 means number of cylinder)
(E means electronic control)
(T means engine having turbo)
(A means engine have after cooler)
(G means engine have an alternator)
T-L type power van
This van is used for the power supply of economy coaches.
45kVA DG or 100kVA digi

Following company Diesel generator are used in power vans for generating
electricity:
 Perkins.
 Caterpillar.
 Cummins.
crafting.
Quality Management
standard.

Safety at Work
procedures.
 In this shop they do not protect their eyes from light of molten metal.
 There is no fire extinguishers and emergency exit in the Power Plant shop.
Work Experience in Power Plant shop C&W shop
The main function of a Power Plant shop is to check the fault of power van and
resolve it for use this again. I work with Mr. Abubakar, the foreman, who briefs me on
all the basic operations of the power plant and its sections. I also look at how overhaul
the generator of power van and power output test of power van generator. Basically 2
companies are use their engine in power van first one is Perkins and second one is
Cummins.

HEAT TREATMENT SHOP
Project Carried Out in Heat Treatment Shop
Heat treatment is defined as an operation that involves heating and cooling a metal
or alloy in the solid state to obtain certain desired properties without changing the
composition. Heat treatment is used to change the grain size, change the texture of the
material, and relieve the stress that the material has developed after hot or cold working.
 Heat treatment is done to improve the inefficiency of the mach.
 Improving magnetic and electrical properties.
 To increase resistance to wear, heat and corrosion and more.
Figure 22: HEAT TREATMENT process

Screw coupling process
 Screw coupling should be heated from 810 to
840 C.
 Give 30 mints to Screw coupling soaking time.
 Screw coupling should be cold in oil.
 Down the temperature of Screw coupling
from550 to 650.
 The temperature of oil should be 110 C.
Heat Treatment Process Flow Chart:
Loading
Unloading
Figure 23: Screw coupling process
1. Cleaning
2. Prewash with
coalescence
3. De-phosphate
system
4. Spray rinse
1. Heating
2. Preheating
3. Sock and
diffusion
4. Pre cooling
1. Quenching
(cooling)
2. Post wash
1. Tempering
2. Surface coating

Supervisory Work in the heat treatment Shop
Types of Heat Treatment Processes
Eight different types of heat treatment processes are as follows:
 Annealing
 Normalizing
 hardening
 Tempering
 Nitriding
 Cyaniding
 Carburizing
 Flame hardening
Types of Heat Treatment
Annealing
Annealing is one of the most important heat treatment processes. It is one of the
most commonly used operations in the heat treatment of iron and steel and is described
as a softening process.
Heating from the upper critical temperature to 30 - 50°C and cooling very slowly
by drawing it from the furnace. The main purpose of annealing is to make the steel more
soft and malleable and to relieve internal stresses. This process softens the steel so that it
can be easily machined.

Normalizing
The main purpose of normalizing is to remove the internal stresses created after the
cold working process. In this, the steel is heated to 30 - 50 °C above its upper critical
temperature and cooled in air.
It improves mechanical and electrical properties, machine ability and tensile
strength. Normalizing is a heat treatment process to restore the structure to a normal
state.
Hardening
The main purpose of the hardening process is to harden the steel. In this process,
the steel is heated to 30°-40°C from the upper critical temperature and then quenched in
water or oil and continues to cool to room temperature. This is the opposite process of
annealing.
Tempering
When the hardening process hardens the steel sample, it becomes brittle and has a
higher residual stress. It is an operation used to change the properties of the steel being
hardened by quenching with the aim of increasing the steel's workability.
As a result of tempering or drawing, brittleness is reduced and the internal stress
generated during hardening is removed. After the hardening process, the steel must be
softened.
Tempering is divided into three types according to the steel requirement.

Carburising
In this process steel is heated in presence of carbon atmosphere. This causes carbon
atoms to accumulate on the surface of the metal and harden it.
Purpose of Heat Treatment of Steel
 To improve mechanical properties such as tensile strength, hardness, ductility,
shockresistance and resistance to corrosion.
 Improve mach inability.
 To relieve the internal stresses of the metal-induced during cold or hot working.
 To change or refine grain size.
 Improve magnetic and electric properties.
 Increase resistance to wear, and corrosion.
 To increase the surface hardness.
crafting.

Quality Management
standard.
Safety at Work
procedures.
 In this shop they do not protect their eyes from light of hot metal.
 There is no fire extinguishers and emergency exit in the heat treatment shop.
Work Experience in heat treatment shop C&W shop
The main function of a heat treatment shop is to increase or decrease the softness or
hardness of material. I work with Mr. Amjad, the foreman, who briefs me on all the
basic operations of the heat treatment shop and its sections. I also look at how Furness
heat up the material that decrease its hardness. Basically 2 Furnace are used in this shop
first one is Batch furnace and second one is box type.

ROLLER BEARING SHOP
Project carried out in Roller Bearing shop
Removal of bearing from wheel
Maintenance of rolling stock is an
important part of railway system. One
cannot imagine what will happen if this is
ignored: stalled trains will block the tracks
and existing timetables will be messed up.
This is why regular maintenance is essential
to maintaining a reliable train fleet.
Engineers will recognize these hazards
when they encounter stuck wheels or
bearings. Cutting or grinding can be dangerous and damage the shaft. Even installing
parts safely can be a challenge. Having the right tools in a rehab facility should be a
priority to ensure reliability and personal safety.
Bega Special Tools specializes in tools for removing and installing bearings and
other transmission components. A number of tools are specially designed for the rail and
metro business to remove and install railway bearing sets, gears, brake discs, labyrinth
rings, etc.
For removing and installing railway bearing sets and labyrinth rings, special
induction heaters can be used. Mid-frequency induction heating technology is a safe and
cost-effective heating method that improves installation quality. Bega Betex
manufactures various models of the MF Quick-heater, also available with fixed or
flexible inductors.
Figure 24: Betex BPP Puller Pusher, used for
installation and removal of railway bearing sets.

Bega offers a unique series of self-centering hydraulic pullers with capacities from
4 to 150 tons for removing gears and train wheels! These pullers are easy to use and
require minimal setup time. Release wheel versions with oil pressure are also available.
Specially designed for loading and unloading railway bearing sets, the Betex
BPP/BPPS is a combined bearing puller and pusher.
Supervisory Work in the heat treatment Shop
Cylindrical roller bearings
These bearings have rollers that are longer than their diameter and can withstand
higher loads than ball bearings. Cylindrical roller bearings can carry heavy radial loads
and are suitable for use in high speed applications.
Figure 25: Cylindrical roller bearing

Spherical roller bearings
It can also carry heavy loads while dealing
with misalignment and shaft deviation. They can
be designed to have a cylindrical or tapered bore
for mounting with or without a sleeve adapter.
Available with various internal clearance and
retention options, spherical roller bearings can
handle axial loading in both directions as well as
heavy shock loads. These bearings are available in
bore dimensions ranging from 20 mm to 900 mm.
Needle roller bearings
This type of bearing is thinner than
conventional roller bearings and can be
designed with or without an inner ring.
Needle roller bearings are ideal for dealing
with radial space constraints in heavy-load,
high-speed applications. The developed cup
styles allow for higher load capacity and
larger grease reservoirs while still offering a
slim cross-section design. These bearings are offered with inch or metric seals.
Figure 26: Spherical roller bearing
Figure 27: Needle roller bearings

Locking system for roller bearing end cap
With the trend toward 125 ton
equipment, tapered roller bearings face even
heavier loading environments. A loose cap
screw can cause loss of lubricant to delay
switch-out or derailment of the hot box. The
Stage 8 locking system provides over 20
times more breakaway torque resistance for
cap screw loosening rotation than a standard
locking plate.
The Stage 8 cap screw locking system is currently under review by the AAR
WABL (Wheels, Axles, Bearing and Lubrication) Committee, and is to undergo field
testing in unit train service. The Stage 8 cap screw locking system represents the first
innovation on a standard locking plate in over 50 years.
crafting.
Figure 28: Locking system for roller bearing end
cap

Quality Management
standard.
Safety at Work
procedures.
 Grasse traces everywhere in shop, very slippery to walk.
 There is no fire extinguishers and emergency exit in the Roller Bearing shop.
Work Experience in Roller Bearing shop C&W shop
The main function of a Roller Bearing shop is to working of the bearings of train
wheel. I work with Mr. Hashim, the foreman, who briefs me on all the basic operations
of the roller bearing shop and its sections. I also look at how to engage or disengage
bearing.

MOTOR SHOP
Carriage and Wagon Motor Shop is responsible for repairing and overhauling cars,
buses, trucks, forklifts and cranes used for Pakistan Railways. This shop mainly consists
of two parts:
 Petrol section.
 Diesel section.
Project carried out in motor shop
Diesel Engine Overhauled
A diesel engine, which is an internal combustion engine that uses heat to ignite
fuel, has an average service life of about 10 years. Diesel engines provide both power
and high efficiency. But wear and tear on engine components over time can lead to
mechanical problems and performance failures. As I start to notice problems with my
diesel engine, the best way to fix them may be to have the engine overhauled. This
procedure involves disassembling the engine, identifying and replacing faulty parts,
cleaning all engine components, and then rebuilding the engine. An overhaul can
increase the performance, strength and longevity of my vehicle. Use this guide to help
you decide when to service your diesel engine.
Figure 29: DIESEL ENGINE OVERHAULED

Mazda index

Supervisory Work in the motor Shop
Difference b/w diesel and patrol engine
The main difference between diesel and petrol engines is that petrol engines use
spark plugs to ignite the air-fuel mixture, while diesel engines rely entirely on highly
compressed air.
As mentioned earlier, Rudolf Diesel found that the temperature of air can be quite
high if it is compressed too much. The temperature will rise to the point where it can
cause ignition of the diesel fuel.
So in diesel engines, the air in the cylinder will be highly compressed, usually
about 14 to 23 times its original volume. In petrol engines, the compression ratio is
usually very low, as they rely more on the spark plug to initiate the power phase. The
compression ratio is that petrol engines are usually only around 7 to 10, high
performance vehicles have a compression ratio of up to 13.
If you notice any of these problems, it's very likely that vehicle should be brought in for
an overhaul immediately:
 Engine spins the rod bearing.
 Engine has very low or no oil pressure.
 Engine has dropped a valve.

Problems Solving
If you notice these symptoms, it's a good idea to talk to a mechanic about the possibility
of repairs:
 Engine is hit hard.
 Engine is using too much engine oil or coolant.
 Put too many miles on your diesel and you are getting poor fuel efficiency.
crafting.

Quality Management
standard.
Safety at Work
The Pakistan Railway workshop is following OSHA rules and other safety
procedures. Workers working in shop with safety rules
 In this shop they protect their eyes from splitting of oil.
 There is a fire extinguishers and emergency exit in the motor shop.
 Workers are working safety shoes and gloves.
 All workers are wearing proper clothes.
Work Experience in Motor shop C&W shop
The main function of a motor shop is to maintain buses and vehicles of Pakistan
railway workshop. I work with Mr. Shahid, the foreman, who briefs me on all the basic
operations of the motor shop and its sections. I also look at over haul the diesel engine.
Basically 2 sections of this shop first one is petrol and second one is diesel.

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