A group of 15 visited Bangladesh Railway as a part of Industrial Training from CUET. This is the presentation slide covering things learned in 3 weeks of training. Pahartali Carriage and Wagon Workshop and Divisional Mechanical Engineer (Loco) Chattogram office were the key locations.

1. INDUSTRIAL ATTACHMENT PRESENTATION
ON
Bangladesh Railway
June 6th, 2022
01

2. 02
Training Locations
DME (Loco) Chattogram Office
 Divisional Train Control Room
 Pahartali Locoshed
 CGPY Locoshed
Pahartali Carriage & Wagon Workshop
 Different Shops related to C&W
TOUKIR/1603096

3. Pahartali Carriage
& Wagon Workshop
03
TOUKIR/1603096

4. 04
DME (Loco)
Chattogram Office
TOUKIR/1603096

5. Pahartali Carriage & Wagon Workshop
PAINT SHOP
For painting both carriage and wagon to:
❖ Prevent the surface from corrosion.
❖ Prevent the surface from Wear-Tear.
❖ Prevent the surface from Harmful Insects
❖ Reflect heat & light.
❖ Produce aesthetics look (formal nice to look at) of surface.
❖ Produce New Life.
KEY PURPOSE PAINT COMPOSITION
❏ Pigment
❏ Binder
❏ Solvent
❏ Additives
05
Painting is done each time a train enters the workshop for scheduling
Fig.: Paint shop
TOUKIR/1603096

6. Pahartali Carriage & Wagon Workshop
PAINT SHOP
PAINTING PROCEDURE
A specific workflow is maintained here for 12 consecutive days
06
Fig.: Painting procedure
TOUKIR/1603096

7. Pahartali Carriage & Wagon Workshop
PAINT SHOP
07
Fig.: A newly painted glossy intercity train
TOUKIR/1603096

8. Components of Locomotive
Bangladesh Railway, Chattogram
• Traction Motor
• Fuel Tank
• Air Compressor
• Turbo Charging
• Governor
• Diesel Engine
• Main Alternator
• Auxiliary Alternator
• Batteries
• Rectifiers
08
MUBASSIR/1603084

9. Components of Locomotive
Bangladesh Railway, Chattogram
• This is the locomotive’s primary source of
power.
• The engine is a V8 two-stroke internal
combustion engine.
Diesel Engine:
09
Figure: Diesel Engine
MUBASSIR/1603084

10. Components of Locomotive
Bangladesh Railway, Chattogram
• The main alternator, which supplies the electricity to propel the train, is
driven by the diesel engine.
• The alternator creates alternating current (AC) electricity, which is
needed to power the traction motors on the trucks (bogies).
Main alternator:
10
MUBASSIR/1603084

11. Components of Locomotive
Bangladesh Railway, Chattogram
• This supplies AC power to the train's lighting,
heating, and air conditioning among other
things.
• Auxiliary alternators are installed on
locomotives that operate passenger trains.
Auxiliary Alternator:
11
Figure: Auxiliary Alternator
MUBASSIR/1603084

12. Components of Locomotive
Bangladesh Railway, Chattogram
• Rectifiers are needed to convert the AC output from the primary alternator to
DC.
• If the motors are DC, the rectifier output is used immediately.
• The rectifiers' DC output is converted to 3-phase AC for the traction motors if
the motors are AC.
Rectifier:
12
MUBASSIR/1603084

13. Components of Locomotive
Bangladesh Railway, Chattogram
• There are four traction motors in a diesel-
electric locomotive.
• Traction motors are provided on the axles
to give the final drive.
Traction Motor:
13
Figure: Traction Motor
MUBASSIR/1603084

14. Power Transmission
Bangladesh Railway, Chattogram
14
Power transmission diagram
MUBASSIR/1603084

15. Pahartali Carriage & Wagon Workshop
Scheduling(C&W)
LE, POH, GOH, Special repair of carriage and
wagon
KEY PURPOSE TOOLS USED
scheduling needs no tools. Dates are stored
in database for next schedule.
ADDITIONAL INFORMATION
Some auxiliary shops are used to complete a
schedule work. Like paint shop, lighting shop etc.
15
JAMIL/1603014

16. DME (Loco)
Scheduling(Loco)
Trip inspection, C schedule, E schedule, special repair
KEY PURPOSE TOOLS USED
Last schedule repair date is stored in
database
16
ADDITIONAL INFORMATION
Light schedule of loco engine is done in loco
shed pahartati. Heavy schedule like GOH, POH is
done in parbatipur.
JAMIL/1603014

17. DME (Loco)
TRIP INSPECTION
KEY PURPOSE TOOLS USED
Generally there is no tool that is used for the
trip inspection for locomotive. The whole
inspection process is done by eyes.
17
THINGS INSPECTED
In DME loco shed
Fuel tank, main generator gearbox, gear casing clamp, lub oil,
water level, governor oil are checked during trip inspection.
To detect any malfunctions or failure points on
the vehicle to keep both the drivers safe and
prevent expensive repairs.
NUHASH/1603022

18. Locoshed
DME(Loco)
A locomotive or engine is a Rail transport vehicle that provides the motive power
for a train.
Traditionally,a locomotive pulles train from the front, at the rear or at each end.
The front may have one or two locomotives followed by a mid train locomotive that
is controlled remotely from the control unit.
General overview of a Locomotive
18
SABBIR/1603108

19. DME (Loco)
Why 2-stroke engine is used in a Locomotive ?
19
i.To get high starting torque
ii.To decrease the size of the engine
iii.To decrease the manufacturing and maintainance cost
iv.To reduce the complexity of the engine
SABBIR/1603108
Locoshed

20. DME (Loco)
20
SL no Series Number of Loco Power(hp) Builder company
01 3000 30 2200 Hyundai Rotem
02 2900 33 1500 Hyundai Rotem
03 2700 21 1500 Henschel Adtranz
04 2600 15 1500 GMD
05 2200 17 875 GMD
06 2000 09 1125 GMD
Different types of Locomotive used in BR(East Zone)
SABBIR/1603108
Locoshed

21. DME (Loco)
21
SL No Name of the components Dimension/type
01 Bore 230.19 mm
02 Stroke 254mm
03 Angle between banks 45 degree
04 Compression ratio 14.5:1
05 Rotation CCW
06 Firing order 1-5-3-7-4-8-2-6
07 Exhaust valves per cylinder 4
SSpecification of 2900 series Locomotive
SABBIR/1603108
Locoshed

22. DME (Loco)
22
SL No Name of the components Dimension/type
08 Main Bearings 5
09 Scavenging Uniflow
10 Fuel Pump Positive Displacement
11 Cooling system Pressurized water cooled
12 Water pumps centrifugal
13 Lubricating oil system Full pressurized
14 Fuel injection Unit Injector with needle valve
Specification of 2900 series Locomotive(cont.)
SABBIR/1603108
Locoshed

23. Pahartali Carriage & Wagon Workshop
WHEEL SHOP
KEY PURPOSE TOOLS USED
ADDITIONAL INFORMATION
23
 Repairing defective wheels
 Wheel fitting
 Bearing maintenance
 Wheel Lathe Machine
 Vertical Boring Machine
 Special Type of Lathe machine with Two headstocks and tool post
 During boring 1 mm negative allowance is maintained between Rim and Tire
 Wheel Press Machine
 Wheels to be fitted with a minimum pressure of 10 tons per inch of axle diameter
 Tire fixing Rolling Machine
 Tire to be rolled with the pressure of 2500 psi.
 Bearing Extracting Machine
 Overhead Crane
 Furnace
NAYEM/1603058

24. Pahartali Carriage & Wagon Workshop
MACHINE SHOP
 Creating hexagonal nut
 Creating square nut
 Thread cutting in different screws
 Thread cutting in break arm
 Turning operation
 Creating half circular beam
KEY PURPOSE TOOLS USED
• Center Lathe Machine
• Turret Lathe Machine
• Capstan Lathe Machine
• Screwing Machine
• Slotting Machine
• Shaper Machine
• Universal Milling Machine
• Radial Drill Machine
SECTIONS OF MACHINE SHOP
 Turning section
 Fitting section
 Machining section
24
SUDIPTO/1603087

25. Pahartali Carriage & Wagon Workshop
FOUNDRY SHOP
In Foundry Shop needed jobs such as break
block, connecting pin are prepared by melting
and pouring metal into molds.
KEY PURPOSE TOOLS USED
Cope and drag, aluminum dies, rammers,
vent rod etc.
ADDITIONAL INFORMATION
It has two sections, Ferrous Section & Non-ferrous Section. For Ferrous Section they use Cupola
Furnace and Crucible Furnace for Non-Ferrous Section. The Non-Ferrous Section is currently not
active. In this shop sand molded casting is used. Cast iron is used in ferrous section. Scrap and pig
iron are also used. This shop specializes on break blocks.
.
25
OEYS/1603089

26. Fig: Carriage Shop
CARRIAGE SHOP
 Periodic overhauling (POH)
 General overhauling (GOH)
 LE
 Wheel repairing
 Balancing under gear
KEY PURPOSE TOOLS USED
 Plate cutting machine
 Lifting jack
 Welding Machine
 Multispindle Drilling Machine
 Hammers
 Chisels
26
RAYHAN/1603125

27. CARRIAGE SHOP
POH (Periodic overhauling): Intercity : 4 years, Mail Express: 6 years. POH must be
completed within 27 working days.
GOH(General overhauling): This is a type of full carriage body repair that occurs every 12
years both Intercity and Mail Express carriages. This will take 45 days to complete.
LE : This type of repairing occurs during POH repairs. There are 3 types of LE repairing.
• LE-1
• LE-2
• LE-3
27
RAYHAN/1603125

28. Fig: GOH repair
RAYHAN/1603125
28
CARRIAGE SHOP

29. Wagon Shop
WAGON SHOP
● Wagon shop dismantles, repair and
assembles wagons.
● The repacking of wagons is done in the
interval of 6 months
● POH is done in the interval of 3.5 years.
KEY PURPOSE Repairments Done in Wagon Shop
In wagon shop various parts of the vehicle
are repaired. Such as cantilever beam,
springs, bushes, wagon body, underframe,
chassis etc.
A table turner is used to move the bogie
from one platform to another.
29
UDAY/1603039

30. Wagon Shop
WAGON SHOP
Fig : Inside of Wagon Shop
Some Insights of Wagon Shop
● It is a huge workshop
● At Least 300 workers can easily work inside
but only 30-40 workers are working here
every day.
● All equipments used here are not up to date
at all
30
UDAY/1603039

31. Wagon Shop
WAGON SHOP
Fig : Wagon Shop
31
UDAY/1603039

32. Pahartali Carriage & Wagon Workshop
Carriage Heavy Repair Shop
● To repair heavily damaged carriages
● To repair carriage that can’t be repaired in
carriage shop
● To execute schedule maintenance.
KEY PURPOSE TOOLS USED
● Plate cutting machine
● Multi spindle drilling machine
● Guillotine shearing machine
● Lifting jack
● Overhead crane
32
Fig: CHR shop
MUBEEN/1603106

33. Pahartali Carriage & Wagon Workshop
Carriage Heavy Repair Shop
TYPES OF JOB DONE
33
Schedule name Time required (Days) Interval (Years)
Lift Enamel ( LE) 15 1
Periodical Overhaul (POH) 27 4
General Overhaul (GOH) 50 12
Special Repair According to job Whenever Necessary
Fig: Carriage Undergoing GOH
MUBEEN/1603106

34. Pahartali Carriage & Wagon Workshop
SMITHY SHOP
A smithy shop is a place metal is heated and
given required shape , especially to make tools.
It creates object primarily from wrought
Iron or steel .
1. Heating
2. Shaping
3. Bending
4. Forging
KEY PURPOSE TOOLS USED
1. Furnace or Hearth
2. Anvil
3. Hammers
4. Tongs
5. Chisels
6. Punches and Drifts
7. Flatters
8. Swage Block
34
RIFAT/1603090

35. Pahartali Carriage & Wagon Workshop
SMITHY SHOP
Smithy shop consists of three sections-
1. Chain section
2. Forging section
3. Spring section
● Chain section does profile gas cutting both
Manual or computerized.
● Forging section helps to make strong,
enduring tools.
● Spring section is used to make coil-spring,
Leaf-spring etc.
● Arc or gas welding also held here.
Sections of Smithy shop
35
RIFAT/1603090

36. Pahartali Carriage & Wagon Workshop
GOH Shop
❖ Repairing carriages after a long
time being passed.
❖ All types of repair: Panel repair,
sheet repair, damaged sheet
repair, roof sheet repair, body
furnishing etc.
KEY PURPOSE:
TOOLS USED
● Plate/Sheet cutting machine
● Multi spindle drilling machine
● Shaper machine
● Drilling machine
Required time for those repairing:
➢ GOH Shop: 45 days
➢ POH Shop: 27 days
➢ LE Shop: 15 days
36
Fig: Welders working on GOH Shop
MAHTAB/1603061

37. GOH Shop
GOH Shop
37
Time span:
● GOH: After 12 years
● POH : After 3 years
● LE shop: After 1 year
Key Operations:
● GOH: Repairing all kinds of damage.
Repairing the panels, sheets, damaged
sheets over the roof, furnishing etc.
● POH :The bathroom, ceiling, and floor.
Observations:
➢ Lack of workforce
➢ Lack of machining tools
➢ In adequate funding
➢ The GOH shop is not too active in
Pahartoli, Chittagong.
Fig: Almost 80 years old carriage
in GOH Shop MAHTAB/1603061

38. Pahartali Carriage & Wagon Workshop
Progress Shop
● Named as the brain of Workshop
● All kinds of document, job card, process of
carriage and wagon control from here
● When a coach come into the workshop, they
do an inspection and send letter to specific
shop where need to repair this coach
KEY PURPOSE
TOOLS USED
➢ Job Card
➢ Progress Card
➢ Gate Pass or Delivery Card
OTHER INFO
➢ Progress shop has the job of receiving a carriage when it is
brought to the workshop for repair or maintenance. The
progress shop then makes a schedule and hand the
carriage over to the carriage shop. The progress shop also
maintains life card and job card.
38
TUSHER/1603052

39. DME (Loco)
Progress Shop
39
OTHER INFO:
LIFE CARD:
Each rake has a life card. The life card
for rakes can be compared with the birth
certificates. The life card contains date at
which the train started service. The date a
carriage comes in for special repair, lift
enamel, POH or GOH and the date it
leaves the workshop are noted in life
card.
JOB CARD:
The job card contains the details of the
job. For example, number of new parts
needed, which shops will take part in
the repair process etc.
TUSHER/1603052
Progress Shop

40. 40
Pahartali Carriage & Wagon Workshop
GATE PASS:
The gate pass is given when a train is enough fit to run
effectively. It is only given when it is ensured that the
train will run without any type of risk and discomfort. This
gate permission is provided by the progress shop
considering all risk variables.
TUSHER/1603052
Progress Shop

41. Pahartali Carriage & Wagon Workshop
CGPY(Chittagong Goods Port Yard)
● Inspection of the locomotive and wagon
intended for goods travelling
● Maintaining goods safety and proper load
distribution.
KEY PURPOSE TOOLS USED
❖ BTL
❖ BC
❖ Special BC
❖ Container
ADDITIONAL INFO
Load distribution is done by marshalling and
shanting
41
MOHAIMIN/1603107

42. Thanks for
attending!