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Afaq report.pdf Supervised Industrial Training
1. 1
Industrial Training Report
Name : SYED Afaq Hussain Shah Gillani
Roll NO : 19au027
Industrial Training Course : supervised industrial training
Training Period : 16 Weeks
Training Organization : Pakistan Railway
2. 2
Abstract
I have very good experience in Railway workshop. There are many types of work are
doing in the railway workshop. During the training I have coverd different shops like
Foundry shop, Tool shop, Power plant shop, Heat treatment shop,E&dc shop, Diesel
rehibition shop, Roller bearing shop, Diesel classified repair shop, Central Laboratory,
Power plant shop, Motor shop
In these shops I was different work experiences like material testing in Spectrometry
machine, Wheel Installation process, hardness and tensile making in furnace etc.
3. 3
Acknowledgement
This Report has been prepared of the Industrial Training that has been done in the
Pakistan Railway Workshop to study the practical aspect of the course and
implementation of the theory in the field with the purpose of fulfilling the requirements
of the degree of BSc. Automotive Engineering Technology. I would like to express
my sincere gratitude to my teacher assistant professor Mr. Muhammad Shafi, ATC
Mr. Muhammad Ashraf in MET PR, all Forman, Charge man, and other staff
members who helped me for their support and encouragement.
Secondly I would also like to thanks my parents and friends who helped me a lot in
finishing this report within the limited time.
I am making this report not only for marks but to also increase my knowledge.
THANKS AGAIN TO ALL WHO HELPED ME.
4. 4
Table of Contents
Abstract.................................................................................................................................... 2
Acknowledgement................................................................................................................... 3
Ch no 1 ..................................................................................................................................... 7
Introduction ......................................................................................................................... 7
Background .......................................................................................................................... 8
Hierarchy or Organogram .......................................................................................... 12
Chapter no 2 .......................................................................................................................... 13
Training Schedule............................................................................................................... 13
Duties in different shop ..................................................................................................... 13
Ch. no 3 Work Experience...................................................................................................... 23
Training Week: 1st ............................................................................................................. 23
Training Week: 2nd............................................................................................................ 24
Training Week: 3rd............................................................................................................. 25
Training Week: 4th............................................................................................................. 26
Training Week: 5th............................................................................................................. 27
Training Week: 6th............................................................................................................. 28
Training Week: 7th............................................................................................................. 29
Training Week: 8th............................................................................................................. 30
Training Week: 9th............................................................................................................. 31
Training Week: 10th........................................................................................................... 33
Training Week: 11
th
............................................................................................................ 34
Training Week: 12th........................................................................................................... 35
Training Week: 13th........................................................................................................... 36
Training Week: 14th........................................................................................................... 37
Training Week: 15th........................................................................................................... 38
Training Week: 16th........................................................................................................... 39
Training Week: 17th........................................................................................................... 40
Ch. No 4 Project Carried Out.................................................................................................. 42
Projects .............................................................................................................................. 42
Project 1: How to Do the Spectrometer Analysis .......................................................... 42
Project 2: Wheel Changing of Diesel Locomotive (ZCU 20, ZCU 30):............................. 43
5. 5
Project no. 3: How to make the C&W Bearing in foundry shop .................................... 44
Project 4: Pins Heat treatment process:........................................................................ 45
Supervisory Work............................................................................................................... 47
Hand on Skills acquired...................................................................................................... 47
How to improve productivity in Organization ................................................................... 47
Quality Management system in railway: ........................................................................... 48
Problem encounter and Problem solving .......................................................................... 49
Safety at work:................................................................................................................... 50
Chapter no 5 .......................................................................................................................... 52
Conclusion:......................................................................................................................... 52
Recommendation:.............................................................................................................. 52
CH 6 References..................................................................................................................... 53
Appendix ................................................................................................................................ 54
7. 7
Ch no 1
Introduction
The history of Pakistan Railways dates back to the British colonial era. The first
railway line was laid in 1858 between Karachi and Kotri, and since then, the network
has expanded to cover most of the country.
Certainly! Pakistan Railways is the national railway of Pakistan and operates both
passenger and freight services. It is the country's largest transportation organization,
with over 7,000 kilometers of track and 450 stations. The railway system is divided
into eight divisions, each with its own headquarters.
Figure 1 Pakistan Railway
8. 8
Background
Pakistan Railways was founded in 1861 during the British Raj. It is one of the oldest
railway systems in South Asia.
Pakistan Railways is a state-owned railway company in Pakistan operating more than
7,000 kilometers of track. It serves all four provinces of Pakistan and operates both
passenger and freight trains. The railway system has faced financial and operational
challenges in recent years, but the government is working to improve its infrastructure
and service.
Pakistan Railways has been undergoing a major transformation in recent years. The
government has invested billions of dollars to upgrade the system, including the
purchase of new locomotives, passenger coaches, and freight wagons. The railway is
also working to modernize its signaling and communication systems. These
improvements are expected to make the railway safer, more reliable, and more
efficient.
The Pakistan Railway workshop are located in Mughalpura Lahore. This workshop are
established in 1908.The area of this railway workshop is 198Acres.This workshop
consist of 3 Departments. The name of the departments is given below:
1. Carriage and wagon Shop
2. Loco Shop
3. Central Laboratory
The Departments of Railway Workshop are explained is given below:
1. Carriage and Wagon Shop:
9. 9
The carriage and wagon shop is the department of Railway workshop. In
this carriage and wagon shop we are repairing the Boogies of train, Ac,
Power Busses, also making the parts of bogies etc.
There are following shops in this Carriage Shops below as:
Spring shop
Black Smith Shop
Power Plant Shop
Bearing Shop
Tool Shop
Heat Treatment Shop
Motor Shop
Wheel Shop
2. Loco Shop:
In this Departments repairing the engines of train, Inspection, Fault
Diagnosing, and engine overhauling etc.
There are following shops in this Loco Shops below as:
E&DC Shop
Tool Shop
Foundry Shop
Diesel Classified Repair Shop
Rehibition Shop
Black Smith Shop
Engine Block Shop
3. Central Laboratory
There are two types of testing are performed in Central laboratory
1-Physical mechanical testing
2-Chemical testing
These testing are explained below.
2-Chemical testing:
10. 10
In chemical testing two methods to perform chemical testing 1st
is Spectrometry
Machine and 2nd
is Wet conventional method. These methods are also performed in
ASTM.This is a National Organization is a Part of ISO (International Standard
Organization).
1-Wet Conventional Method:
In this method different types of elements has been testing like zinc (Zn) Carbon (C)
etc. The Wet Conventional Method are performed in two ways 1st is Combustion and
2nd is Titation. In which testing a Lab person checking which quantity of carbon, iron
etc. are available in the piece of metal as per as Specification. In which each person
have to test performed each element it means 4 persons has to perform as per as 4
element. This process has to perform with different gadgets like Test tube, Flask,
Burner, Chemical etc. Each element has different temperature to testing. So this testing
method is very time consuming because 4 tests give the result after 4 days.
Spectrometry Machine
This is an Iron based machine. In which all types of iron based material pieces has
been checked like Aluminum (Au),Copper(C), Nickel (Ni),Zinc (zn),Lead (pb) etc. as
per as Specification. This machine has to Reducing the working as well as time
duration. This machine are connected to the Computer. This computer have to
checking 1 elements in a few Seconds.
Physical Mechanical Testing:
The Physical Mechanical testing are testing in different methods like 1st is
Tensile/Yield and 2nd is Hardness.
These method are explain below.
1-Tensile/Yield:
In this method the pull the piece of metal and checking the breaking point. For the
checking of breaking point of piece of metal the UTM 9Universal Tensile Testing
Machine) has been used.
2-Hardness:
11. 11
In Hardness a method is used to checking the hardness of a piece of metal through
Brinell Steel Ball (HB). In which machine drilling in the piece of metal like a hole.
The metal give the resistance against drilling. So that hole help to checking the
hardness of a piece of metal
12. 12
Hierarchy or Organogram
AWMG AWMC
WM
AWMP
Foreman Foreman Foreman
Charge Man Charge Man
Skilled
Workers
Charge Man
Worker
Figure 2 Organogram
13. 13
Chapter no 2
Training Schedule:
Sr
No.
Name of Shops Period of Training
1
Central Laboratory MGPR 27-03-2023 to 30-03-2023
2
Power Plant Shop C&W Shop 31-03-2023 to 10-04-2023
3
Motor Shop C&W Shop 11-04-2023 to 30-04-2023
4
Heat Treatment Shop C&W Shop 01-05-2023 to 09-05-2023
5
Roller and Bearing Shop C&W Shop 10-05-2023 to 20-05-2023
6
Diesel Classified Repair Shop Loco
Shop
21-05-2023 to 10-06-2023
7
E&DC Shop Loco Shop 11-06-2023 to 17-06-2023
8
Tool Shop Loco Shop 18-06-2023 to 24-06-2023
9
Foundry Shop Loco Shop 25-06-2023 to 06-07-2023
10
Diesel Rehibition Shop Loco Shop 07-07-2023 to 10-07-2023
Duties in different shop
Central Laboratory MGP:
Sample Collect
Chemical Testing
14. 14
Material Testing
Fuel Testing
Liquid Testing
Figure 3 Central Laboratory
Power Plant Shop C&W Shop:
Electrical Testing
Mechanical Testing
Power Buses Repairing
15. 15
Figure 4 Power plant
Motor Shop C&W Shop:
Railway Buses Engine overhauling
Body Repairing
16. 16
Figure 5 Motor shop
Heat Treatment Shop C&W Shop:
Making Hardness of Material
Forging
Change in Surface
17. 17
Figure 6 Heat treatment shop
Roller and Bearing Shop C&W Shop:
Installation of Wheel Bearing
Cleaning of Bearing
Removing of Wheel Bearing
19. 19
Figure 8 locomotive engine
E&DC Shop Loco Shop:
Engine Parts Making
Oil seal
Friction plate
Discharge valve
Valve guide
Plunger lubricant
Bearing shell con rod
Con rod bush
Rooter shaft
All types of bushes
Crank shaft of compressor
21. 21
Figure 10 Tool shop
Foundry Shop Loco Shop:
Melting Material
Making Dies
22. 22
Figure 11 Foundry shop
Diesel Rehibition Shop Loco Shop:
Inspection of trains’ engines
Paint
23. 23
Ch. no 3 Work Experience
Training Week: 1st
Daily Entry
It’s my first day at MET College introduction
with teachers
Today I have attend the class about the history
of Pakistan Railway and introduction of
existing workshops in Pakistan Railway
Today my 1st
day in Power Plant shop (C&W) and
introduction with staff
Today I learn about the basic system operation use
in power plant shop
I learn how to work Diesel generator
Today I learn identification of diesel generator
parts and how many brands use in Pakistan
Railway
24. 24
Training Week: 2nd
Daily Entry
Today I learn about the control systems of generators
use in Pakistan railway
Today I learn about the circuit breaker control panel and
their specifications
Today I learn safety factor use in motor shop and how to
work in motor shop
Today I learn basic difference in diesel and petrol engines
Today I learn how to check engine oil radiator
coolant and also know how check the vehicle
through visual inspection.
Today I learn how to disassemble diesel engine for
engine overhauling.
25. 25
Training Week: 3rd
Daily
Entry
I learn sign of diesel engine may be weak and
need to be overhaul or need to be change
Today I learn sign of petrol engine maybe weak
and need to be overhaul or need to be replace.
Today I learn how to piston ring adjustment
in diesel engine
Today I learn how to adjustment of timing of
diesel engine during overhauling.
Today I learn method of petrol engine overhauling
and how to adjust ignition timing during engine
overhauling
Today I learn how to inspect engine after
overhauling.
26. 26
Training Week: 4th
Daily Entry
Today I learn about the safety factor use in heat
treatment shop
Today I learn how to work in heat treatment shop
and know what are the operation perform in heat
treatment shop
Today I learn about how to increase resistance in
metal
Today I learn how to mechanical and electrical
properties of metal and how to increase the
machinability properties increase
I learn how to done annealing process for the
softening of metal , steel and copper and learn what
are the basic temperature use for this process.
27. 27
Training Week: 5th
Daily Entry
Today I learn how to done normalizing process for
decrease the internal stress develop after the cold
working process
Today I learn how to do hardening process for the
steel and matel toughness
Today I learn how to do tempering and nitriding
process in matel
Eid al-Fitr Holiday
Eid al-Fitr Holiday
Eid al-Fitr Holiday
28. 28
Training Week: 6th
Daily Entry
Eid al-Fitr Holiday
Today I learn how to do cyanding and carburizing
process
Today I learn purpose of these process in metal
and steel
I learn about the types of furnaces and which
material use for making these furnaces
Identification of parts of the locomotive engines
use in Pakistan railway
Today I learn introduction of locomotive shop
and which kind of shops in locomotive block
29. 29
Training Week: 7th
Daily Entry
Introduction with team of locomotive diesel shop
Today I learn about the basic specification of engines use
in Pakistan railway
I identify the sensor use in locomotive engine
Identification of parts of the locomotive engines use in
Pakistan railway
I learn about electrical system and their working
I learn about 6 month engine inspection checking point
Today I learn about diesel injection pump and its
working
30. 30
Training Week: 8th
Daily Entry
Today I learn how to inspect cylinder head valve
and valve guide
Today I learn how to check water jackets and elbows
through visual inspection and then through different
types of test
Today I learn how to check oil level oil and oil condition
in locomotive CAT&Piller engines
Today I how to dismantle locomotive engine for the
overhauling
Today I learn how to inspect engine internal parts after
dismantling the locomotive engine
Today I learn how to check crankshaft and camshaft
inspection method
31. 31
Training Week: 9th
Daily Entry
Today I learn how to inspect ring and piston and
play between the connecting rod and main journal
Today I learn how to fix the any king of seepage
on engine. I learn the seepage fixing of oil sump.
Today I learn about the diagnosing and fixing of
We Diagnose the engine oil comes from Engine
timing Side (Engine front Side). We replaced the
Oil seal to fix it.
Today I fix or re assemble the engine with
complete overhauling and check the any kind of
leakage and seepage
Today I learn about how to check all basic systems
after the engine overhauling
Today I get an overview of engine
Troubleshooting
Engine misfire with abnormal internal lower
noises.
33. 33
Training Week: 10th
Daily Entry
Today I learn about the fault diagnose of
lubrication system and check the the all leakages
and seepages in system
Today I learn about the compression testing of
new assemble engine during the final inspection
of engine
I learn how to get an dry and wet compression test
Today I learn turbocharger function in locomotive
engine
I learn how to work of turbocharger in locomotive
engines
I learn how to diagnose the fault of turbocharger in
locomotive.
34. 34
Training Week: 11th
Daily Entry
I learn about the cooling system of locomotive
Today I learn about the main fault of cooling system
and how to fix them
I learn how to replace water pump in locomotive
engines
I learn how to check thermostat valve and water
jackets
I learn how to work diesel lift pump in locomotive
Today I learn flywheel inspection of locomotive
engines
35. 35
Training Week: 12th
Daily Entry
Today i learn inspection of wheel assembly
.
I learn how check bearing play in wheel assembly
I learn how to dismantle the wheel bearing from
wheel assembly
I learn how to load test on a bearing
I learn how to refit bearing in wheel assembly
I learn how to check bearing after refitting on wheel
36. 36
Training Week: 13th
Daily Entry
Introduction with the staff of Tool shop
I learn parts identification of Lathe Machine
I learn how to make an clutch and flywheel hosing
and what are the basic operation use in clutch
housing
I learn how to do facing process
I learn how to drilling and honing process
I learn how turning and knurling process
37. 37
Training Week: 14th
Daily Entry
I learn how to check work piece after completing the
work
I learn how to do operation on specific angles
I learn how working a pneumatic tools
I learn how to cutting the tool on shaper machine
How to inspect the tool after completing the process
38. 38
Training Week: 15th
Daily Entry
Introduction with the team of E&DC Shop
Here I learn purpose of friction plate and how to
make it
I learn how to make an oil seal valve guide and
plunger.
I learn how to make bearing shell connecting rod
I learn how to face a crankshaft of parkins and
commins engine
Today I learn how to check dimension of crankshaft
after facing
39. 39
Training Week: 16th
Daily Entry
Introduction with the foundry shop team and I learn
what are the safety factor in foundry shop
I learn how to make a mold and what type of
material use for making the mold and also know
how to inspect a mold after completing this
Today I learn how to melt a iron for
molding
Today I learn ow to check a brake system in train
I learn how to test vacuum and pressure brake
system during the half year inspection
I learn how to check traction motor and learn
how its work
40. 40
Training Week: 17th
Daily Entry
I learn how to dismantle traction motor and how to
change their stater
I learn how to refit the traction motor and inspect
again for final inspection
I learn how to check overhaul bogie inspection
I learn how to inspect boggie suspension system and
how to check shock absorber
I learn how to inspect fuel tank and Ac system during
the inspection
42. 42
Ch. No 4 Project Carried Out
Projects
Project 1: How to Do the Spectrometer Analysis
Preparing the samples
Turn ON the machine and warm it let sit for at least 15 minutes before running
any sample
Get the Deionized water
Clean the cuvettes or test tube with Deionized water
Use different pipettes for each sample to prevent cross contamination
Load the proper volume of the sample into cuvettes or test tubes
Prepare a control solution known as Blank: has only the chemical solvent in
which the solute to be analyzed is dissolved in.
Use Lint free cloth to wipe the outside of the cuvettes or test tube for dust
particles
Running the Experiment
Choose and set the Desired wavelength according to specification
Calibrate the machine with Blank
Place Blank into cuvettes holder inside the spectrometer and shut the lid
Set the Blank to outside the adjustment knobs
Remove the Blank and test the calibration
Be sure the calibrated reading stay 0
Now place the test sample inside the machine
Waite 10s until the digital numbers stops changing
Record the value of %transmittance and/or absorbance
Repeat the test with successive wavelength of light
Repeat your reading at 25 nm intervals across the spectrum
Analyze the data you can absorbed through machine
Calculate the Transmittance and absorbance of sample through T= l/l 0 and
A=log10
Place the Absorbance value vs. the wavelength on graph
Compare the absorbance spectrum place to known place of specific compound
43. 43
Figure 12 UV - Spectrometry Machine
Project 2: Wheel Changing of Diesel Locomotive (ZCU 20, ZCU 30):
Dismantle all the shock absorber (Primary, Secondary, Vertical)
Lifting the Upper body of locomotive which included Engine unit, Expresser,
Radiator etc.
Lifting the bogie chaises
a. If I change ZCU 20 wheel so first of all I clamp the Axle box with chaises
b. Firstly I have to left out the secondary spring in ZCU 30
c. If I change ZCU 30 so first of all I have to titan the axle box spring with
chaises
In both locomotives I have disassembled the pull rod from wheel to body
After that disassembling the pull rod chaises of bogie is totally free from wheels
and traction motors
Left out the traction motor
Dismantle the gear box
Dismantle the axle box, axle bearing, axle housing etc.
After above all procedures are done the all parts are disassembled from wheel
44. 44
Now I check all the parts if they are in working good condition or not
Now I have to install new wheel
After changing the wheel now I have to assembled all these parts
Project no. 3: How to make the C&W Bearing in foundry shop
There are following procedures are to making the C&W bearing in foundry shop:
Firstly I have to check the bearing pattern to helping the making of bearing
Making the core or mold according to bearing pattern
After making the core I have to get the material for using to make the bearing
like Copper85%, Tin6%, Zinc5%, Lead5%, PH.CU0.1%
Getting all these material with correct ratio
Now putting above all material in the furnace
After putting the total materials in the furnace. Now ON the furnace
Now I will getting temperature in furnace at 1050c
When the temperature of furnace are reached to 105c. Now the material are in
melting position
After that we have Off the furnace
Now I have to getting the helping Tool for picking the melting material from
furnace
I also getting the core or mold that I have making before all that procedures
After this I have to get all the melting material with helping Tool and putting
into the core
After putting that material into the core
I will wait and watch until the material will be in cold or solid position
If the material in cold or solid position now I have to put out the bearing into
the core
Now the bearing is ready
45. 45
Figure 13 Mold making
Figure 14 Furnaces
Project 4: Pins Heat treatment process:
Get all types of pins
46. 46
Putting the pins into the furnace
After putting into the furnace then turn ON the furnace
Heat the pins at 800 to 850c Temperature of furnace
When the temperature of furnace reach at 800 to 850c then putt out the pins
from the furnace
Now after the putting out the pins from furnace then I have to soaking the pins
into the water from 30 to 40 minutes
The pins are soaking into the water and the temperature of water is 27 to 43c
After soaking the pins at specific temperature the pins are again put into the
furnace
Now the temperature of the furnace is 400 to 425c
Again repeat the soaking process in 30 to 40 minutes
Now the pins are soaking in the normal air
Figure 15 Pins
47. 47
Supervisory Work
It has manage the flow of work in workshop
Making the team schedule and manage it
He gave the reports of all about of work doing in workshop to HR and senior
manager
Evaluate the performance and providing the feedback
Solving all the problems of employees
Hand on Skills acquired
Learning the Management
Be Professional and also positive attitude
I learn to change the wheel
I learn the working of spectrometry machine
I learn to change the Bearing
Determination
Good leadership to perform in our opportunity
Be strong in mind
How to improve productivity in Organization
Proactive Employee
Identify the and aligns goals and performance
Good working condition
Good Tools and equipment’s to making raise the productivity
48. 48
Good relation with employees
Giving facility to employees
Making good environment in workstation
Be careful with safety precautions
Strength communication protocols
Give the right people to right task
Encourage learning opportunities
Quality Management system in railway:
When the any part of locomotive engine or body are damaged so they are change
or replace the new part. Pakistan is considered on the sixth number in most populated
countries around the globe. Due to the high population, there’s an increase in the
demand for traveling of people in Pakistan.
Pakistan railway system is giving more importance to maintenance as customers want
to enjoy better services and better quality of products due to growing importance of
quality in our life. To measure the quality of services of railways in Pakistan, the key
determinants are customer satisfaction and retention.
Railways are considered the cheapest and most environmentally friendly mode of
transportation. It helps to transport the bulk of goods from one place to another over
long distances without any significant impact upon the environment. Rail is also one
49. 49
of the transportation modes which is emission efficient and there are electric trains that
are powered by renewable energy.
Problem encounter and Problem solving
1. Engine Overheat
Cause.
Checking cooling, system
Checking lubrication system
Check fuel system
Remedies.
Repair the thermostat valve
Repair the oil filter
Repair the excessive amount of fuel system
2. Engine doses not running
Cause.
Check the starting motor
Check the battery
Remedies.
Repair the starting motor
Repair the battery
3. Engine blow by
Cause.
Check the piston
Check the piston rings
Check the cylinder liner
50. 50
Remedies.
Repair the piston
Repair the piston rings
Repair the cylinder liner
4. Engine pre ignition
Causes.
Check the cooling system
Check the lubrication system
Check the fuel system
Remedies.
Repair the fault of engine cooling system like thermostat valve, lack of
coolant etc.
Repair the fault of lubrication system like oil transmission pump, lack of
oil etc.
Repair the fault of cooling system like excessive amount of fuel are going
in the cylinder
Safety at work:
Don’t wear lose clothes
Wear shoes
Be alert with environment
Keep open your eyes with activeness
Safely with slippery surfaces
Wear gloves
Wearing the hamlet, glasses, gloves before work in welding shop
Keep clean the work place
Use the specific tools for work
All the extra scraps are throwing into the scrap bin
51. 51
Don’t use your hands for stopping the machine
Whistling during the Overhead crane and shunting
52. 52
Chapter no 5
Conclusion:
This training focused upon increasing our knowledge and interest in toward the
Production of Railway Carriage & Wagons and workshops. Because It is most efficient
and necessary needs to peoples in these days so its production at most efficient method
with minimum cost and in proper sequence with less wastage. It was a great
experience. It increases my practical skills that are the main thing which i learnt in the
training session. Thus, I believe that my training session will be beneficial for various
purposes & hence our efforts will be fruitful. Finally I would like to thank my
instructor and all the person of this organization who had helped me lot during my
course
Recommendation:
Making good management
Use latest machinery
Make clean environment
Apply rules and regulations with every person or employee
53. 53
CH 6 References
1. Christian Wolmar, Blood, iron, and gold: How the railroads transformed the
world (Public Affairs, 2011).
2. ^ "Sweet Track". Severn Estuary Levers Research Committee. Retrieved 30
September 2016.
3. ^ Brunning, Richard (2006). "A window on the past – The prehistoric
archaeology of the Somerset Moors". In Hill-Cottingham, Pat; Briggs, Derek;
Brunning, Richard; King, Andy; Rix, Graham (eds.). The Somerset Wetlands:
An ever changing environment. Wellington, Somerset: Somerset Books. pp. 40–
41. ISBN 978-0-86183-432-7.