This internship report summarizes the work done during an internship at the Mughalpura Railway Works in Lahore, Pakistan. The internship provided hands-on experience in various workshops including the diesel classified shop, foundry shop, E & DC shop, and spring shop. Key activities included learning about locomotive parts and operations, inspecting production processes, and understanding maintenance schedules. The report describes the functions of each workshop and manufacturing processes like casting, machining, and spring production. It aims to connect theoretical knowledge to practical applications in the railway industry.

1. DEPARTMENT OF MECHANICAL TECHNOLOGY

2. DEPARTMENT OF MECHANICAL TECHNOLOGY
Locomotive
Railway Works
AHMED ALVI
2013-UET-KIT-MECH-24
ENGR.IRFAN KHATAK
Contact +92 322 6857041 email;ahmedalvi3@gmail.com

3. DEPARTMENT OF MECHANICAL TECHNOLOGY
Abstract
This report describes the work conducted during the internship at the
mughalpura railway works. This internship is part of the degree.The
main purpose of my internship report is to clear the concept and try to
explain Railway works.
I learned about how locomotives and their parts work.
I came to know different types of locomotives.
I learned and inspect all the workshops process.

4. DEPARTMENT OF MECHANICAL TECHNOLOGY
Aims & Objectives
The objectives of internship are to interconnect my theoretical
knowledge to the practical field and understand the parameters of
Railway workshops work and their operations and to know about
railway engine etc….
The main objective of this internship is to understand locomotive train
engine .
To study on workshops operations.
To understand industrial production.
The aim of the internship is to study the production process.

5. DEPARTMENT OF MECHANICAL TECHNOLOGY
Schedule of internship
Sr.No Name of shops Period of training
1 Diesel classified shop 26/1/17 to 3/2/17
2 Foundry shop 4/2/17 to 15/2/17
3 E & DC shop 16/2/17 to 28/2/17
4 Spring shop 01/3/17 to 10/3/17

6. DEPARTMENT OF MECHANICAL TECHNOLOGY
Literature Review
History
The Moghalpura Railway Workshops are one of several
Pakistan Railways rolling stock repair sites, located on the
Lahore–Wagah Branch Line at Moghalpura Junction railway station in
Lahore, Pakistan. The workshop complex began to emerge at its
present site in 1904 in order to manufacture, repair and overhaul
passenger coaches and freight wagons for the then
North Western State Railway. After Pakistan's independence in 1947, it
was the only state-of-the-art workshop for Pakistan Railways
.

7. DEPARTMENT OF MECHANICAL TECHNOLOGY
Department During
Internship
The departmnts and sections where I spend my time and inspect are
following:
 Locomotive department
 Foundry department
 Electric and diesel shop
 Spring department

8. DEPARTMENT OF MECHANICAL TECHNOLOGY
Workshops in mughalpura
locomotive works
Diesel classified and rehabilitation shop
Power assembly shop
High capacity wagon shop
Machine shop
Foundry shop
E&DC shop
Spring shop
Wheel shop
Machine maintinence shop

9. DEPARTMENT OF MECHANICAL TECHNOLOGY
ORGANIZATIONAL
STRUCTURE:

10. DEPARTMENT OF MECHANICAL TECHNOLOGY
Diesel classified shop
The responsibility of diesel classified work shop is overhauling of all
locomotives of Pakistan Railways after every 5 years. In diesel classified
shop there are different section that perform preventive maintenance
of different parts.

11. DEPARTMENT OF MECHANICAL TECHNOLOGY
DIESEL LOCOMOTIVE
A diesel locomotive is a type of railway locomotive in which the prime
mover is a diesel engine. Several types of diesel locomotive have been
developed, differing mainly in the means by which mechanical power is
conveyed to the driving wheels.

12. DEPARTMENT OF MECHANICAL TECHNOLOGY
TYPES OF
LOCOMOTIVES
s.no Name of locomotive Code
number
Manufacuerd by
01 Hitachi bambordian universal HBU-20 America
02 General motor canedian universal GMCU-15 Caneda
03 Diallanpakistan universal DPU-30 China
04 Zialliancoaporation universal ZCU-30 China
05 American locomotive universal ALU-95 America
06 Re-engineering general electric GRE-20 Caneda
07 Green tiger AG-30 America

13. DEPARTMENT OF MECHANICAL TECHNOLOGY
SECTIONS OF DIESEL
CLASSIFIED
There are following sections of diesel classified shop. Each section
performs its
respective operation.
1. Power Assembly Section
2. Electric Section
3. Crank Shaft Section
4. Radiator Section
5. Nozzle Section
6. Engine Governor Section

14. DEPARTMENT OF MECHANICAL TECHNOLOGY
Schedule of maintenance
Each of these locomotives having different class of power from 1500HP
to 3000HP, but now pakistanrailway added a new class of loco having
power upto 4000 HP known as (GE-40) Perchased from America. Most
of these locomotives are four stroke diesel engine and GMCU-15 is
only a two stroke diesel engine.
Minimum period Duration
After every trip For six hours
After one month For eight hours
After three month For one day
After six month For three days
After one year For one week

15. DEPARTMENT OF MECHANICAL TECHNOLOGY
Types of Diesel Engine
Diesel engine is divided into two types
Vertical engine
V-type engine
Vertical engine
In this types the engine is fitted in verticledirection.each connecting rod
is clamp with a separate journal.these engines are
ALCO-95 6 cylinder four stroke
ALCO-12 6 cylinder four stroke
HAU-10 6 cylinder four stroke

16. DEPARTMENT OF MECHANICAL TECHNOLOGY
Types of Diesel Engine
V-type engine
The cylinder of these engines are mounting on a same journal like v
shape at a angle of 45digree.
Fllowing engines are v-type engine
AG-30
GMU-30
ALU-24
ZCU-30

17. DEPARTMENT OF MECHANICAL TECHNOLOGY
Parts of diesel engine
Diesel engine is consist on following parts:
crank case
 cylinder block
crank case motor
crank shaft
connecting rod
main bearing
piston and piston rings
cam shaft

18. DEPARTMENT OF MECHANICAL TECHNOLOGY
Parts of diesel engine

19. DEPARTMENT OF MECHANICAL TECHNOLOGY
Foundry Shop
In foundry shop different types of parts are produced using casting
process. After casting the work pieces are machined to convert them
into various parts according to part structure. Various types of furnaces
are available in at Loco shop of railway industry to cast different
number of parts accordin g to demand.
.

20. DEPARTMENT OF MECHANICAL TECHNOLOGY
TYPES OF FURNACES
There are different types of furnaces available in foundry shop. The
furnaces are as follow:
 Cupola Furnace
 Tilt Furnace
 Rotary furnace

21. DEPARTMENT OF MECHANICAL TECHNOLOGY
Cupola Furnace:
A cupola or cupola furnace is a melting device used in foundries that
can be used to melt cast iron and some bronzes. The cupola can be
made almost any practical size. The shell of the cupola, being usually
made of steel and has refractory brick. The bottom is lined in a similar
manner but often a clay and sand mixture.temp 3000f

22. DEPARTMENT OF MECHANICAL TECHNOLOGY
Tilting Furnace:
A tilt furnace is also a melting device used in foundries that can be used
to melt aluminum and some bronzes. It is called tilts furnace because
molten metal can be get by tilting the furnace. The cupola can be made
almost any practical size.. 550-600faluminum
Brass melting temp=1050-1150f

23. DEPARTMENT OF MECHANICAL TECHNOLOGY
Rotary furnace:
Rotary Melting Furnace is very flexible & universal equipment used
forrecycling many non-ferrous metals. Rotary Furnace is a batch type
process furnace. It is designed according to capacity. In Rotary Furnace
the required quantity of raw material is filled along with a
proportionate charge of additives. It is used to melt raw iron.

24. DEPARTMENT OF MECHANICAL TECHNOLOGY
PARTS MADE IN
FOUNDRY SHOP

25. DEPARTMENT OF MECHANICAL TECHNOLOGY
PARTS MADE IN BRASS
FOUNDRY
There are following parts are prepared in this shop:
Sliding door handle
Upper birth handle
Coat hook
Window catcher
Window stopper
Window panel
Glass stand
Motor cover

26. DEPARTMENT OF MECHANICAL TECHNOLOGY
PARTS MADE IN IRON
FOUNDRY
There are following parts are prepared in this shop:
L.P cylinder for D.E loco
H.P cylinder for D.E loco
Oil tank cock body
Disc brake
Brake shoes
Caps for alternator body
Brake block
Plug for oil tank cock body

27. DEPARTMENT OF MECHANICAL TECHNOLOGY
E &DC SHOP
In this shop all parts related to diesel engine are preared and machined
here:
Parts prepared and machined here are:
oil seal
friction plate
discharge valve
valve guide
planger lubricant
bearing shell

28. DEPARTMENT OF MECHANICAL TECHNOLOGY
Sections in E &DC SHOP
grinding section
milling section
lathe section
Machines used in E & DC SHOP
Hydraulic machines
Vertical milling machines
Bench lathes
Center lathes

29. DEPARTMENT OF MECHANICAL TECHNOLOGY
SPRING SHOP
in this shop all types of springs are prepared and manufactured here
Springs are flexible machine element used for controlled application of
force or torque or for storing and release of mechanical energy.

30. DEPARTMENT OF MECHANICAL TECHNOLOGY
Types of spring
The following types of springs are prepared here:
Buffer spring
Coil helical spring
Leaf spring

31. DEPARTMENT OF MECHANICAL TECHNOLOGY
SPRING MAKING
PROCESS
There are following steps used in making of springs
1.Cutting
2.Heating of coil head
3.Heating in bar heating furnace
4.Coiling of spring
5.Spacing of coil
6.Hardening of coil
7.Tempring
8.Scrag test

32. DEPARTMENT OF MECHANICAL TECHNOLOGY
Spring making process
9. Load test
10. Finishing/grinding
11. painting

33. DEPARTMENT OF MECHANICAL TECHNOLOGY
1.cutting
In cutting the material is cutted in requried size:

34. DEPARTMENT OF MECHANICAL TECHNOLOGY
2.Heating of coil head
In this step head of coil is made in heating furnace:

35. DEPARTMENT OF MECHANICAL TECHNOLOGY
3.Heating of coil
In this step the coil is heated in bar heating furnace and the
tempreature is 860c to 900c.

36. DEPARTMENT OF MECHANICAL TECHNOLOGY
4.Coiling of spring
This process is done on double bar lathe machine after heting.

37. DEPARTMENT OF MECHANICAL TECHNOLOGY
Coiling of spring

38. DEPARTMENT OF MECHANICAL TECHNOLOGY
5.SPACING

39. DEPARTMENT OF MECHANICAL TECHNOLOGY
6.Hardening of coil spring
In this step the coil spring is diped into oil.

40. DEPARTMENT OF MECHANICAL TECHNOLOGY
7.Tempring
In this step the coil is tempred into the temper furnace.480-510c

41. DEPARTMENT OF MECHANICAL TECHNOLOGY
9.Grinding finishing

42. DEPARTMENT OF MECHANICAL TECHNOLOGY
Contact details of
person(s) incharges
Diesel classified shop:
Sikandar hayat (forman mechanical) diesel classified shop.
Muhammad nafees (charge man) 0300-4804758.
E &DC Shop:
Basharat rasheed (forman)
Foundry shop:
Muhammad imtiaz (Forman)
Spring shop:

43. DEPARTMENT OF MECHANICAL TECHNOLOGY
Future Recommendations
for junior Students
Pakistan railway is the best place to learn all mechanical work.this is the
house of mechanical workshops.

44. DEPARTMENT OF MECHANICAL TECHNOLOGY
References
 "$8.2b railtrack upgrade project wins go-ahead - The Express
Tribune". The Express Tribune. 2016-06-08. Retrieved 2016-06-23.
Wikipedia: Narrow gauge
railwayhttp://www.pildat.org/publications/publication/GovernanceAss
essment/PerformanceAnalysisofPakistanRailways.pdf
Liszewski, Andrew (15 March 2017). "The Reason Trains Have Angled
Wheels Is Incredibly Clever". Gizmodo. Retrieved 14 March 2017.
http://www.pakrail.com/ybook2.pdf

45. DEPARTMENT OF MECHANICAL TECHNOLOGY