Final lab Report19AU006.pdf Supervised Industrial Training

Punjab Tianjin University of
Technology Lahore
Pakistan Railway Mughalpura Lahore
Name Taimur Ali
University Roll No. 19AU006
Department Automotive Engineering And Technology
Industrial Training COURSE SUPERVISED INDUSTRIAL TRAINING
Training Period 27-03-2023 To 23-07-2023 (16 Weeks)
Training Organization Pakistan Railway Mughalpura
INDUSTRIAL TRAINING REPORT

Abstract
The record is written and associated with my experience as consistent with the 2023
internship requirement at (LOCOMOTIVE WORKSHOP). Which is part of my 'BSc
Automobile Engineering course. The record consists of a whole focus on locomotive
vegetation in 'Mughalpura Lahore'. This document is based on the paintings revel in
of various "LOCOMOTIVE" workshops which give the essential understanding
approximately the "RAILWAY WORKSHOP" device, This internship document is to
document the info of my industrial training which was finished in Pakistan Railway
Workshop which is one of the maximum reputed commercial workshops in Pakistan.
This document will contain the details of my internship in the Locomotive and Wagon
branch for 4 months (16 weeks) at Pakistan Railway Workshop located at Mughalpura,
Lahore.
This course is designed for college students finishing the BSc diploma. Automotive
Engineering and Technology in Punjab Tianjin University of Technology Lahore, are
required to go through business training at one time for 4 months earlier than
commencement.

Acknowledgements!
To start with I would really like to thank Allah Almighty who blessed me and
enabled me to complete this work. After this, I’m thankful to the foreman, supervisors,
and in-fee guys of all departments of Pakistan Railway Workshops for growing
opportunities for me to be inducted into this esteemed agency.
It gives me tremendous pride to pay tribute to all the workforce individuals operating in
the Railway branch for showing such passion and enthusiasm in the direction of their
area of labor. His help in guiding me with the technical elements of the work executed
within the workshop is substantially appreciated. This helped me considerably in
completing my record.
Thanks to all who made this education feasible for me particularly all the individuals
of Punjab Tianjin University of generation?

Contents
Abstract......................................................................................................................................2
Acknowledgements!..................................................................................................................3
Objective of the Report ............................................................................................................1
Objective of the Training:........................................................................................................1
1. Talent development: .....................................................................................................1
2. Protection awareness:...................................................................................................1
3. Knowledge Workshop techniques:..............................................................................2
4. Troubleshooting and hassle-fixing: .............................................................................2
5. Familiarization with device:.........................................................................................2
CHAPTER #01......................................................................................................................3
Background of Railway Pakistan ............................................................................................3
Background:..............................................................................................................................3
Partition and Formation of Pakistan Railways:.....................................................................4
Modernization and increase: ...................................................................................................4
Challenges and Decline: ...........................................................................................................4
Revival Efforts: .........................................................................................................................4
Future Outlook: ........................................................................................................................5
Railway Board and Organogram:...........................................................................................6
CHAPTER #02......................................................................................................................7
Schedule of Training, Duties as Trainee.................................................................................7
Schedule of Training: ...............................................................................................................7
Duties as Trainee: .....................................................................................................................8
Chapter # 03 ..........................................................................................................................9
Weekly Training Book..............................................................................................................9
Training Week 1.........................................................................................................................9
Training Week 2.........................................................................................................................9
Training Week 3...................................................................................................................... 10
Training Week 4...................................................................................................................... 10
Training Week 5...................................................................................................................... 11
Training Week 6.................................................................................................................. 11
Training Week 7.................................................................................................................. 12
Training Week 8.................................................................................................................. 12
Training Week 9.................................................................................................................. 13
Training Week 10................................................................................................................ 13

Training Week 11................................................................................................................ 14
Training Week 12................................................................................................................ 14
Training Week 13................................................................................................................ 15
Training Week 14................................................................................................................ 15
Training Week 15................................................................................................................ 16
Training Week 16................................................................................................................ 16
Training Week 17................................................................................................................ 17
Chapter # 04 ....................................................................................................................... 18
1. Diesel Classified Work Shop......................................................................................... 18
Power assembly section:.................................................................................................... 18
Electrical section:............................................................................................................... 19
Governor section:............................................................................................................... 19
Air compression section: ................................................................................................... 19
Traction Motor: ................................................................................................................. 19
2. E&DC SHOP LOCO SHOP ..................................................................................... 21
Lathe Machines:................................................................................................................. 21
Lathe machine.................................................................................................................... 21
Specifications:..................................................................................................................... 21
Parts of lathe machine:...................................................................................................... 22
Operations of lathe machine:............................................................................................ 22
Types of Lathe Machines................................................................................................... 22
1. Centre lathe:............................................................................................................... 23
2. Bench lathe ................................................................................................................. 23
3. Turret lathe................................................................................................................. 24
4. Capstan lathe.............................................................................................................. 24
Repairing ............................................................................................................................ 24
Grinding Section:............................................................................................................... 25
Operations:......................................................................................................................... 25
 Surface Grinding: ...................................................................................................... 25
 Cylindrical Grinding: ................................................................................................ 26
 Internal Grinding: ..................................................................................................... 26
 Thread Grinding:....................................................................................................... 26
3. Tool Shop.................................................................................................................... 27
Lathe Machines.................................................................................................................. 27
Types of Lathe Machines............................................................................................... 28

1. Centre lathe ............................................................................................................ 28
3. Capstan lathe.......................................................................................................... 29
Milling machine.............................................................................................................. 30
Types of Milling Machine.............................................................................................. 31
I. Vertical mill............................................................................................................ 31
II. Horizontal milling machine............................................................................... 31
III. Universal milling machine................................................................................. 32
Shaper machine.............................................................................................................. 32
4. Diesel Rehabilitation Shop Loco Shop ................................................................. 33
Diesel Locomotive and it's working.................................................................................. 33
Locomotives Use by Pakistan Railway............................................................................. 33
ES43ACI Engine:............................................................................................................... 33
EMD Engine:...................................................................................................................... 34
ENGINE CONFIGURATION:......................................................................................... 34
Classification of Railways Locomotives........................................................................... 35
3000 H.P V-Type 16 Cylinders Locomotives:.................................................................. 35
2000 H.P V-Type 12 Cylinders Locomotives:.................................................................. 35
1200 H.P V-Type 6 Cylinders Locomotive: ..................................................................... 35
List of Safety Devices in Working Order: ....................................................................... 35
5. Foundry shop.............................................................................................................. 40
Parts prepared in a brass foundry ................................................................................... 41
Parts prepared in an iron foundry ................................................................................... 41
Casting:............................................................................................................................... 42
Casting process................................................................................................................... 42
Pattern: ............................................................................................................................... 42
Different types of patterns: ............................................................................................... 43
Mould preparation: ........................................................................................................... 43
Mould preparation: ....................................................................................................... 43
Sand used in the moulding process............................................................................... 43
Green sand mould:......................................................................................................... 44
Dry sand mould:............................................................................................................. 44
Materials used in mould preparation........................................................................... 44
Furnaces used in the foundry workshop...................................................................... 44
Tilting furnace................................................................................................................ 44
6. Power Plant Shop................................................................................................... 45

Power Plant Introduction.................................................................................................. 45
Turbo Supercharger and its Working Principle............................................................. 46
Main Components.......................................................................................................... 47
Rotor Assembly.............................................................................................................. 47
Lubricating System........................................................................................................ 47
Cooling System............................................................................................................... 47
7. Heat Treatment Shop C&W Shop........................................................................ 48
Steps in heat treating operation.................................................................................... 48
Loading:.............................................................................................................................. 48
Heating:............................................................................................................................... 49
Cooling:............................................................................................................................... 49
Finishing: ............................................................................................................................ 49
Types of Heat Treatment Processes ................................................................................. 49
Annealing:........................................................................................................................... 50
Normalizing:....................................................................................................................... 50
Hardening:.......................................................................................................................... 51
Tempering: ......................................................................................................................... 51
Case hardening or surface hardening:............................................................................. 52
8. Roller Baring Shop C&W Shop................................................................................ 53
Roller Bearings: ................................................................................................................. 53
Roller Bearing Types and Application............................................................................. 54
1. Cylindrical Roller Bearings: ..................................................................................... 54
2. Spherical Roller Bearings: ........................................................................................ 55
3. Needle Roller Bearings:............................................................................................. 55
4. Taper Roller Bearings:.............................................................................................. 56
Suspension .......................................................................................................................... 56
9. Motor Shop C&W Shop............................................................................................ 59
Petrol section ...................................................................................................................... 59
Diesel section ...................................................................................................................... 59
Low-pressure side components......................................................................................... 61
High-pressure side components........................................................................................ 61
Pump drive ......................................................................................................................... 61
Lubricating system............................................................................................................. 62
Oil pressure ........................................................................................................................ 62
Low Oil Pressure................................................................................................................ 62

10. CENTRAL LABORATORY MGPR ....................................................................... 63
Sample Collection and Testing: ............................................................................................ 63
Quality Control Analysis:...................................................................................................... 63
Chemical Analysis:................................................................................................................. 64
Material Testing:.................................................................................................................... 64
Environmental Monitoring:.................................................................................................. 64
Testing: ................................................................................................................................... 64
Fuel Viscosity: ........................................................................................................................ 65
Viscosity Index:...................................................................................................................... 65
Hydraulic Testing: ............................................................................................................. 67
How Productivity can enhance in this Project:............................................................... 68
Safety at work: ................................................................................................................... 68
Pneumatic Test:.................................................................................................................. 68
How Productivity can enhance in this Project ................................................................ 73
Safety at Work: .................................................................................................................. 73
Chapter # 05 ....................................................................................................................... 74
Conclusion:......................................................................................................................... 74
Recommendations:............................................................................................................. 75
Chapter # 06 ....................................................................................................................... 76
References: ......................................................................................................................... 76
Training Certificate ............................................................................................................... 77

Table of Figure
Figure 1- Railway Pakistan............................................................................................ 3
Figure 2- Railway Workshop......................................................................................... 5
Figure 3- Organogram Diagram..................................................................................... 6
Figure 4- Training Schedule .......................................................................................... 7
Figure 5- Diesel Calssified Shop ................................................................................. 18
Figure 6- Cylinder Liner .............................................................................................. 18
Figure 7-Piston............................................................................................................. 18
Figure 8- Air Compressor............................................................................................ 19
Figure 9- Traction Motor ............................................................................................. 19
Figure 10- DC Traction Motor..................................................................................... 20
Figure 11- E & DC Shop ............................................................................................. 21
Figure 12- Lathe Machine............................................................................................ 22
Figure 13- Center Lathe............................................................................................... 23
Figure 14- Turrent Lathe.............................................................................................. 24
Figure 15- Grinding Section ........................................................................................ 25
Figure 16- Grinding Operation .................................................................................... 26
Figure 17- Tool Shop................................................................................................... 27
Figure 18- Center Lathe............................................................................................... 28
Figure 19- Turrent Lathe.............................................................................................. 29
Figure 20- Milling Machine......................................................................................... 30
Figure 21- Vertical Milling Machine........................................................................... 31
Figure 22- Horizontal Milling Machine....................................................................... 31
Figure 23- Universal Milling Machine ........................................................................ 32
Figure 24- Locomotive Engine .................................................................................... 34
Figure 25- Diesel Engine Governor............................................................................. 36
Figure 26- Speedo Meter ............................................................................................. 37
Figure 27- Guages........................................................................................................ 38
Figure 28- Foundary Shop ........................................................................................... 40
Figure 29- Parts Prepared In Brass Foundary.............................................................. 41
Figure 30- Parts in Iron Foundary................................................................................ 41
Figure 31- Casting Process .......................................................................................... 42
Figure 32- Pattern ........................................................................................................ 43
Figure 33- Mould Preparation...................................................................................... 43
Figure 34- Tilting Furnance......................................................................................... 44
Figure 35- Power Plant ................................................................................................ 45
Figure 36- Turbo Charger............................................................................................ 46
Figure 37- Heat Treatment Shop.................................................................................. 48
Figure 38- Annealing Process...................................................................................... 50
Figure 39- Normalizing................................................................................................ 50
Figure 40- Hardening................................................................................................... 51
Figure 41- Roller Bearing Shop................................................................................... 53
Figure 42- Bearing....................................................................................................... 53
Figure 43- Cylindrical Bearing.................................................................................... 54
Figure 44- Spherical Bearing....................................................................................... 55

Figure 45- Taper Bearing............................................................................................. 56
Figure 46- Primary Suspension.................................................................................... 57
Figure 47- Secondary Suspension................................................................................ 57
Figure 48- Motor Shop................................................................................................. 59
Figure 49- Diesel Engine ............................................................................................. 60
Figure 50- Centeral Laboratory ................................................................................... 63
Figure 51- Chemical Analysis ..................................................................................... 64
Figure 52- Material Testing Lab.................................................................................. 64
Figure 53- Visco Meter................................................................................................ 65
Figure 54- Flash Point.................................................................................................. 66
Figure 55- Hydraulic Testing....................................................................................... 67
Figure 56- Traction Motor ........................................................................................... 70
Figure 57- Armature Testing ....................................................................................... 71

1
Objective of the Report
I. The primary objective of the lab document is to provide a complete report of the
realistic workout or test. It includes info consisting of the date of the activity, the
members concerned, and the particular techniques accompanied at some point of the
exercise.
II. The lab report ambitions to analyse and examine the effects and effects of the
practical exercising. It may consist of statistics, measurements, observations, and
calculations associated with the responsibilities achieved within the workshop.
III. The lab file demonstrates the contributors' understanding and alertness of theoretical
standards learned within the classroom or during previous training classes. It
showcases how they practically enforce their knowledge inside the railway
workshop setting.
IV. For nice control functions, the lab report may additionally consist of facts on the
accuracy and precision of measurements, as well as any deviations or problems
encountered for the duration of the exercise. This data allows perceive regions for
development in workshop procedures.
Objective of the Training:
1. Talent development:
The primary goal of railway workshop education is to expand technical abilities and
abilities required for working in a railway workshop. Contributors learn how to use
diverse tools, equipment, and gadget to carry out protection and repair tasks on
locomotives, carriages, and wagons.
2. Protection awareness:
Safety is of paramount importance in railway workshops, given the presence of
heavy machinery and potentially hazardous obligations. Schooling emphasizes safety
recommendations, protocols, and great practices to make sure the well-being of workers
and the prevention of injuries.

2
3. Knowledge Workshop techniques:
The schooling familiarizes members with the same old running processes and
workflows accompanied in the railway workshop. They advantage insights into the
enterprise, methods, and great manipulate measures concerned in railway preservation.
4. Troubleshooting and hassle-fixing:
Members learn how to pick out and troubleshoot commonplace troubles encountered in
railway operations. The training encourages crucial questioning and trouble-solving
talents to address challenges effectively.
5. Familiarization with device:
Railway workshop training introduces members to the unique equipment, machinery,
and equipment used in the workshop. They discover ways to manage and perform these
assets competently and successfully.

3
CHAPTER #01
Background of Railway Pakistan
Background:
After the partition of British India and the independence of Pakistan in 1947, most of
the North Astern nation Railway infrastructure changed into in Pakistani territory and
become renamed Pakistan Astern Railway. In East Bengal, the portion of the Assam
Bengal Railway in Pakistani territory changed into renamed the Pakistan eastern
Railway. The U.S has followed eight,122 km (5,047 mi) of the North Astern kingdom
Railway; 6,880 km (4,280 mi) changed into 1,676 mm (5ft 6 in), 506 kilometres (314
mi) changed into 1,000 mm (3ft three+3⁄8 in) meter gauge and 736 kilometres (457 mi)
become 762 gam (5ft 6 in).
In 1954 a branch line turned into prolonged from the Karachi-Peshawar railway line to
Madan and Charade. Years
later, the Jacobabad-
Kashmir metre-gauge line
changed into transformed to
at least one, 676 mm (five
toes 6 in) huge gauge. The
Kot Adu-Kashmir section
of the Kotri-Attock railway
line turned into made out of
1969 to 1973, presenting an
alternative route from
Karachi to northern
Pakistan. In 1974, Pakistan
western Railway became renamed Pakistan Railways. In February 2006, the 126-
kilometre (78 mi) Hyderabad–Khokhrapar department line turned into converted to at
least one, 676 mm (5 toes 6 in). All of the use’s slender-gauge tracks have been
converted to at least one, 676 mm (five toes 6 in) or scrapped in the course of the 2000s.
Figure 1- Railway Pakistan

4
On eight January 2016, the Lodharan-Raiwind branch line double-rail challenge was
completed.
The British authorities diagnosed the strategic significance of railways for green
administration, alternate, and military functions. Hence, they began constructing
railway lines in India inside the mid-19th century.
Partition and Formation of Pakistan Railways:
After India won independence from British rule in 1947, the Indian subcontinent
changed into divided into two separate countries, India and Pakistan. The department
of the railway community became a challenging challenge, as many strains surpassed
thru the newly created borders. Pakistan Railways become installed because the
countrywide railway machine for the newly fashioned us.
Modernization and increase:
Within the early years of independence, Pakistan Railways underwent sizeable
expansion and modernization. New railway lines have been built, and the gadget turned
into upgraded with modern locomotives and rolling inventory. During this period,
Pakistan Railways become one in every of the largest employers in the United States of
America and performed a critical role in the financial development of Pakistan.
Challenges and Decline:
In the latter 1/2 of the 20th century and early twenty first century, Pakistan Railways
confronted numerous challenges, such as financial problems, loss of funding, getting
older infrastructure, and competition from different modes of transportation. Those
challenges led to a decline within the railway's efficiency and profitability.
Revival Efforts:
To revitalize the railway gadget, the Pakistani authorities initiated numerous revival
plans and tasks. There have been efforts to enhance infrastructure, introduce current era,
and beautify passenger services. Moreover, steps had been taken to boom public-private
partnerships to draw funding and enhance operations.

5
Future Outlook:
As of my final replace in September 2021, Pakistan Railways persevered to work in the
direction of modernization and development of its offerings. The government remained
devoted to investing inside the railway quarter and exploring opportunities for nearby
and global connectivity via railway links.
Railway Workshops:
The workshop was established in the late 19th century to cater to the maintenance and
repair needs of the burgeoning railway network in the region.
During the British rule, the railway played a crucial role in connecting different parts of
the Indian subcontinent, and Lahore
was an essential hub for railway
operations. To support the ever-
growing railway infrastructure and
ensure smooth functioning of the
railways, workshops were set up at
various strategic locations.
The Mughalpura Railway Workshop
was one such facility established in
Lahore. It was named after the nearby
Mughalpura locality, which holds
historical significance due to the presence of Mughal-era structures.
Over the years, the workshop expanded and modernized to keep up with the demands
of a growing railway system. It played a vital role in maintaining and repairing
locomotives, carriages, and wagons, ensuring the safety and efficiency of train
operations.
After the partition of British India in 1947, when Pakistan emerged as a separate nation,
the Mughalpura Railway Workshop came under the control of the newly formed
Pakistan Railways. The workshop continued its operations and played a crucial role in
the development of Pakistan's railway infrastructure.
Figure 2- Railway Workshop

6
Railway Board and Organogram:
The Railway Board, which existed from 1959 to 2000, turned into replaced via a
government committee in 2000 and 2014. On 20 February 2015, the Railway Board
become reinstated. The board participants are:
 Federal Secretary Railways (Chairman of the Board)
 Federal Secretary for Communications
 Finance Minister of Pakistan
 Secretary planning and improvement Pakistan
 Director standard of Railways (Operations)
Member of Finance, Ministry of Railways This composition could not get the approval
of Parliament and at present the Board includes ex. The officio member listed above
with 3 members from the personal region appointed by the authorities. Mystery
Railways is likewise the Chairman of the Board. The Secretariat of the Board of
administrators is controlled by way of the Secretariat of the Railway Committee. The
headquarters of the Board is Ministry of Railway, Islamabad.
Figure 3- Organogram Diagram

7
CHAPTER #02
Schedule of Training, Duties as Trainee
Schedule of Training:
In this chapter I take a look at my four months training take a look at the workshop
schedule where I do my complete practice.
The details of schedule of training are given below
Figure 4- Training Schedule

8
Duties as Trainee:
As trainee I observed all working process which are undergoing in different workshops.
As trainee I observed and learning about the nature of work analysis of faults comes
during working and there solutions within time management.
I. My primary obligation as a trainee is to examine and study from skilled technicians
and engineers. Be aware of their commands, strategies, and great practices in
railway preservation and restore.
II. I assist professional employees and technicians in wearing out various duties, which
includes recurring maintenance, inspections, and upkeep on locomotives, carriages,
and wagons.
III. I have to discover the ways to handle various tools, system, and machinery used
inside the workshop. Familiarize yourself with their proper utilization and safety
strategies.
IV. I have to keep the workshop vicinity clean and prepared. Proper housekeeping is
important for protection and efficient workflow.
V. Assist in collecting relevant data at some stage in maintenance and restore activities.
This may include measurements, observations, and recording findings for
documentation.
VI. Follow all protection protocols and pointers while working within the workshop.
Prioritize protection to prevent accidents and make sure a safe operating
surroundings.
VII. Apprehend and adhere to traditional working approaches and protocols
accompanied inside the railway workshop.

9
Chapter # 03
Work Experience Week Wise
Weekly Training Book
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 1

10
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
Icompiled our attendance sheet by signing it from
foreman and submitted to clerk office in Diesel
classified shop
Weekly Training Book
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 wrokpiece 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 4

11
Daily Training Book
I went to Tool shop and submitted my
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.
Daily Training Book
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 6
Training Week 5

12
Daily Training Book
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.
Daily Training Book
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
Training Week 8

13
Daily Training Book
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.
Daily Training Book
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 dis assembling and overhauling of
diesel generator.
I learnt about the assembling of the diesel
generator.
Training Week 9
Training Week 10

14
Daily Training Book
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.
Daily Training Book
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 11
Training Week 12

15
Daily Training Book
I went to Roller Bearing shop and submitted my
this shop
I learned about the dis assembling 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.
Daily Training Book
I learned the safety factor of roller bearing shop.
foreman and submitted to clerk office in roller
bearing shop.
Training Week 13
Training Week 14

16
Daily Training Book
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 week or
need to be over hauled.
Daily Training Book
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.
Training Week 15
Training Week 16

17
Daily Training Book
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 methode 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 17

3 Week Work Experience
18
Chapter # 04
1. Diesel Classified Work Shop
In this shop I learned about the responsibility of diesel classified work shop is
overhauling of all locomotives of Pakistan Railways after every 5 years. There are 5
different sections working for diesel
classified.
 Power assembly section.
 Nozzle, fuel Injection & pump
section.
 Governor section.
 Electrical section.
 Air compression section.
Power assembly section:
In power assembly section, I observed the overall engine head, connecting rod, valves, piston,
liner (cylinder) and other parts are totally disassembled and overhauled. If there is any part
which is out lived so it will be replaced e.g. piston rings. Engine parts are transfer to power
assembly section by overhead electric crane (5 & 40 ton capacity). Liner (cylinder) made by
cast iron has ø9.003” and chrome coated internally. Aluminium made piston has ø8.980”,
Figure 5- Diesel Calssified Shop
Figure 7-Piston Figure 6- Cylinder Liner

19
Electrical section:
In this electrical section I observed all electrical default and correct that defaults.
Governor section:
Governor regulates the idling speed and maximum speed of the engine by controlling
the fuel supply. It is tested on machine that how it is working and what are problems
which should correct. Check all 8 notches as well.
Air compression section:
I learned the operation of air compressor and
Air compressors of locomotives that are
repaired or overhauled, it is use for the braking
system of train. There are two types of braking
systems used in Pak railways, air pressure
brakes and vacuum brakes. 6 cylinders
compressor is used for 3000/2000 hip
locomotives. Where 3 cylinders for 70 psi air
pressure and 3 cylinders for 22 lb/inch vacuum.
 6CD3UC compressor.
 6CD4UC compressor.
Traction Motor:
Traction motor refers to a type of electric motor. A traction motor is used to make
rotation torque on a machine. It is
usually changed into a straight line
motion. Traction motors are used in
electrically powered rail vehicles
such as electric multiple units and
electric locomotives. They are also
used in electric vehicles, such as
electric milk floats, elevators, and
Figure 8- Air Compressor
Figure 9- Traction Motor

20
conveyors. Vehicles with electrical transmission systems such as Diesel-electric
locomotives, electric hybrid vehicles and battery powered electric vehicles.
I understand the use of traction motor in train engines Railroad first used DC motors.
These motors usually ran on about 600 volts. High-powered semiconductors were
developed to control the switching of AC motors. They have made AC induction motors
a better choicest’s an induction motor does not require contacts inside the motor. These
AC motors are simpler, and more reliable than the old DC motors. AC induction motors
known as asynchronous traction motors.
Figure 10- DC Traction Motor

1 Week & 6 Days Work Experience
21
2. E&DC SHOP LOCO SHOP
In this shop I observed that all parts related to diesel engine are prepared and machined
here:
Parts prepared and machined here are:
 oil seal
 friction plate
 discharge valve
 valve guide
 plunger lubricant
 bearing shell
 connecting rod
 connecting rod bush
 roter shaft
 all types of bushes
Lathe Machines:
It is a specialized tool used for machining and shaping various rotating electrical
additives. It is a versatile machine able to turning and cutting materials to create
cylindrical shapes, ensuring precise dimensions and easy surfaces. In the context of the
E and DC keep, the lathe gadget is in general used to refurbish and restore critical
components found in electrical systems of locomotives, which include armatures,
commutators, shafts, and other rotating components in traction cars, mills, and
alternators
Lathe machine
Specifications:
 Swing
 Distance between centres
 Length of bed
 Radius ( one of swing)
Figure 11- E & DC Shop

22
Parts of lathe machine:
 Bed and ways
 Headstock and spindle
 Carriage and saddle
 Cross slide and compound
 Tool post and tools
Operations of lathe machine:
 Turning:
 Facing:
 Boring:
 Drilling:
 Threading:
 Knurling:
Different types of lathe machine are used in this shop for various operations
The lathe is a machine tool used principally for shaping articles of metal (and sometimes
wood or other materials) by causing the work piece to be held and rotated by the lathe
while a tool bit is advanced into the work causing the cutting action. The basic lathe that
was designed to cut cylindrical metal stock has been developed further to produce screw
threads. Tapered work. Drilled holes. Knurled surfaces, and crankshafts. The typical
lathe provides a variety of rotating speeds and a means to manually and automatically
move the cutting tool into the work piece. Machinists and maintenance shop personnel
must be thoroughly familiar with the lathe and its operations to accomplish the repair
and fabrication of needed parts.
Types of Lathe Machines
According to my knowledge, Lathes can be divided into three types for easy
identification: operator can accomplish more machining jobs with the engine lathes,
turret lathes, and special purpose lathes. Small engine lathe than with any other machine
tool. Turret lathes lathes can be bench mounted, are lightweight, and can be and special
purpose lathes are usually used in production or transported in wheeled vehicles easily.
The larger lathes are job shops for mass production or specialized parts.
Figure 12- Lathe Machine

23
1. Centre lathe:
I understand that the Centre Lathe is used to manufacture cylindrical shapes from a
range of materials including; steels and plastics. I observed that many of the components
that go together to make an engine work have been manufactured using lathes. These
may be lathes operated directly by people (manual lathes) or computer controlled lathes
(CNC machines) that have been programmed to carry out a particular task. I attached
basic manual centre lathe that is shown below. This type of lathe is controlled by a
person turning the various handles on the top slide and cross slide in order to make a
product / part.
2. Bench lathe
Lathe mounted on a workbench. Lathe - machine tool for shaping metal or wood; the
work piece turns about a horizontal axis against a fixed tool.
Figure 13- Center Lathe

24
3. Turret lathe
The turret lathe is a form of metalworking lathe that is used for repetitive production of
duplicate parts, which by the nature of their cutting process are usually interchangeable.
It evolved from earlier lathes
with the addition of the turret,
which is an index able tool
holder that allows multiple
cutting operations to be
performed, each with a
different cutting tool, in easy,
rapid succession, with no need
for the operator to perform set-
up tasks in between, such as
installing or uninstalling tools, nor to control the toolpath. The latter is due to the
toolpath's being controlled by the machine, either in jig-like fashion, via the mechanical
limits placed on it by the turret's slide and stops, or via electronically-
directed servomechanisms for computer numerical control lathes.
4. Capstan lathe
I observed that the capstan machine is a processing machine used to make the same
parts again and again. The cutting bits are mounted on a rotatable turret known as a
capstan, which permits the client to rapidly change the introduction of the bits for slicing
without needing to take off the first bit and afterward mount the second. I saw a bit of
crude material, off and on again known as a clear, is mounted into the capstan machine
and is then spun at high velocity. The cutting apparatuses, some of the time known as
blades, are then used to slice into the clear to make another shape or outline.
Repairing
 It is used to Repairs and maintenance of electrical components of locomotives.
 General repairs and tests of diesel engines and generators.
 Troubleshooting and repair of electrical faults in locomotives.
 Manufacture and repair of electrical control panels and circuits.
 Tests and calibration of electrical equipment.
Figure 14- Turrent Lathe

25
 Inspection and replacement of defective electrical components.
 Performing preventive maintenance of electrical systems.
Grinding Section:
In gringing section, I noticed that the grinding phase in the E and DC (electrical and
direct modern) store of the locomotive railway in Lahore is a specialized area
responsible for precision grinding operations on diverse electrical additives. I observed
that this section is geared up with
specialised grinding machines which
are used to refine the surfaces of
important elements like armatures,
commutators, and other rotating
components determined in traction
vehicles, mills, and alternators. Skilled
technicians and machinists inside the
grinding phase perform tasks along
with grinding commutator surfaces to
make sure smooth brush contact and top of the line electrical overall performance.
Moreover, they will grind shafts and bearing surfaces to preserve unique dimensions
and right alignment.
Operations:
In a grinding shop, I observed numerous grinding operations that are performed to form,
refine, and end exclusive sorts of materials. Some commonplace grinding operations
include:
 Surface Grinding:
On this operation, a rotating abrasive wheel grinds the surface of a work piece to reap a
flat, easy, or particular end. Floor grinding is generally used to provide flat surfaces on
metallic, plastic, and different materials.
Figure 15- Grinding Section

26
 Cylindrical Grinding:
This system includes grinding the out of
doors diameter of a cylindrical work piece to
attain tight tolerances and an easy surface
end. Cylindrical grinding is used for shafts,
rods, and other cylindrical components.
 Internal Grinding:
I understood under the supervision of
workers that Inner grinding is used to grind
the internal diameter of a work piece to reap
particular dimensions and a smooth surface
end. It is normally used for making
boreholes and different internal features.
 Thread Grinding:
Thread grinding is used to produce correct and particular threads on screws, bolts, and
other threaded components.
Figure 16- Grinding Operation

27
3. Tool Shop
In this shop, I learned that the tool shop is responsible to provide cutting tools of
machines and different types of dies for railways workshops, e.g. drills, shanks for tips,
dies & punches etc. there are 3 precious machines and also 1 engraving machine
 Copy Milling
 Spark Errosion E.D.M (electric discharge machine)
 Wire cut machine
 Engraving machine
Lathe Machines
In tool shop, I observed the section are arranged like first section is lathe machine.The
lathe is a machine tool used principally for shaping articles of metal (and sometimes
wood or other materials) by causing the work piece to be held and rotated by the lathe
while a tool bit is advanced into the work causing the cutting action. The basic lathe that
was designed to cut cylindrical metal stock has been developed further to produce screw
threads. Tapered work. Drilled holes. Knurled surfaces, and crankshafts. The typical
lathe provides a variety of rotating speeds and a means to manually and automatically
move the cutting tool into the work piece. Machinists and maintenance shop personnel
must be thoroughly familiar with the lathe and its operations to accomplish the repair
and fabrication of needed parts.
Figure 17- Tool Shop

28
Types of Lathe Machines
In lathe section, I observed that the lathes can be divided into three types for easy
identification: operator can accomplish more machining jobs with the engine lathes,
turret lathes, and special purpose lathes. Small engine lathe than with any other machine
tool. Turret lathes lathes can be bench mounted, are lightweight, and can be and special
purpose lathes are usually used in production or transported in wheeled vehicles easily.
The larger lathes are job shops for mass production or specialized parts.
1. Centre lathe
The Centre Lathe is used to manufacture cylindrical shapes from a range of materials
including; steels and plastics. Many of the components that go together to make an
engine work have been manufactured using lathes. These may be lathes operated
directly by people (manual lathes) or computer controlled lathes (CNC machines) that
have been programmed to carry out a particular task. A basic manual centre lathe is
shown below. This type of lathe is controlled by a person turning the various handles
on the top slide and cross slide in order to make a product / part.
Figure 18- Center Lathe

29
2. Turret lathe
The turret lathe is a form of metalworking lathe that is used for repetitive production of
duplicate parts, which by the nature of their cutting process are usually interchangeable.
It evolved from earlier lathes with the addition of the turret, which is an index able tool
holder that allows multiple cutting operations to be performed, each with a
different cutting tool, in easy, rapid succession, with no need for the operator to perform
set-up tasks in between, such as installing or uninstalling tools, nor to control the
toolpath. The latter is due to the toolpath's being controlled by the machine, either in jig-
like fashion, via the mechanical limits placed on it by the turret's slide and stops, or
via electronically-directed servomechanisms for computer numerical control lathes.
Figure 19- Turrent Lathe
3. Capstan lathe
A capstan machine is a processing machine used to make the same parts again and again.
The cutting bits are mounted on a rotatable turret known as a capstan, which permits
the client to rapidly change the introduction of the bits for slicing without needing to
take off the first bit and afterward mount the second. A bit of crude material, off and on
again known as a clear, is mounted into the capstan machine and is then spun at high

30
velocity. The cutting apparatuses, some of the time known as blades, are then used to
slice into the clear to make another shape or outline.
Milling machine
Foreman guided me about the machining process of using rotary cutters to
remove material from a work piece by advancing (or feeding) in a direction
at an angle with the axis of the tool. It covers a wide variety of different
operations and
machines, on scales
from small
individual parts to
large, heavy-duty
gang milling
operations. It is one
of the most
commonly used
processes in
industry and
machine shops
today for machining parts to precise sizes and shapes.
And I observed that milling can be done with a wide range of machine tools.
The original class of machine tools for milling was the milling machine
(often called a mill). After the advent of computer numerical control (CNC),
milling machines evolved into machining centers (milling machines with
automatic tool changers, tool magazines or carousels, CNC control, coolant
systems, and enclosures), generally classified as vertical machining centers
(VMCs) and horizontal machining centers (HMCs).Foreman told me about
the integration of milling into turning environments and of turning into
milling environments, begun with live tooling for lathes and the occasional
use of mills for turning operations, led to a new class of machine tools,
multitasking machines (MTMs), which are purpose-built to provide for a
Figure 20- Milling Machine

31
default machining strategy of using any combination of milling and turning
within the same work envelope.
Types of Milling Machine
According to my experience, There are
following types of milling machine
I. Vertical mill
In the vertical mill I observed that the
spindle axis is vertically oriented. Milling
cutters are held in the spindle and rotate on
its axis. The spindle can generally be
extended (or the table can be
raised/lowered, giving the same effect),
allowing plunge cuts and drilling.
Foreman told me that there are two subcategories of vertical mills: the bed mill and the
turret mill.
II. Horizontal milling machine
A horizontal mill has the same sort but the cutters are mounted on a horizontal spindle
(see Arbor milling) across the
table. Many horizontal mills also
feature a built-in rotary table that
allows milling at various angles;
this feature is called a universal
table. While endmills and the
other types of tools available to a
vertical mill may be used in a
horizontal mill, their real
advantage lies in arbor-mounted
cutters, called side and face mills,
which have a cross section rather like a circular saw, but are generally wider and smaller
in diameter. Because the cutters have good support from the arbour and have a larger
cross-sectional area than an end mill, quite heavy cuts can be taken enabling rapid
Figure 21- Vertical Milling
Machine
Figure 22- Horizontal Milling Machine

32
material removal rates. These are used to mill grooves and slots. Plain mills are used to
shape flat surfaces. Several cutters may be ganged together on the arbour to mill a
complex shape of slots and planes. Special cutters can also cut grooves, bevels, radii, or
indeed any section desired. These specialty cutters tend to be expensive. Simplex mills
have one spindle, and duplex mills have two. It is also easier to cut gears on a horizontal
mill. Some horizontal milling machines are equipped with a power-take-off provision
on the table. This allows the table feed to be synchronized to a rotary fixture, enabling
the milling of spiral features such as hypoid gears.
III. Universal milling machine
In Tool shop I understood the working of universal machine and I noticed that the
universal machine can be fitted
with various attachments such
as the indexing fixture, rotary
table, slotting and rack cutting
attachments, and various special
fixtures the basic difference
between a universal horizontal
milling machine and a plain
horizontal milling machine is
the addition of a table swivel
housing between the table and
the saddle of the universal machine. This permits the table to swing up to 45° in either
direction for angular and helical milling operations.
Shaper machine
A shaper is a type of machine tool that uses linear relative motion between
the work piece and a single-point cutting tool to machine a linear tool path.
Its cut is analogous to that of a lathe, except that it is (archetypal) linear
instead of helical.
A metalworking shaper is somewhat analogous to a metalworking planer,
with the cutter riding a ram that moves relative to a stationary work piece
Figure 23- Universal Milling Machine

33
4. Diesel Rehabilitation Shop Loco Shop
In Rehabilitation shop foreman told me that accidental and others damages locomotive
are repairs here as per design and specifications of locomotive. Locomotives who
complete their technical age (25 years) theses locomotive are complete overhauling,
including fabrication works to extend loco age. These projects also done in this shop.
Rehabilitation shop consists of these sections
 Fabrication section
 Welding section
 Electronic and electric section
 Pivot section
Diesel Locomotive and it's working
I visited this shop and foreman guided me that the diesel locomotive is a self-contained
version of the electric locomotive. He also gave me the information of the working
principle of diesel locomotive is actually diesel engine's crank shaft rotates the
alternator like the electric locomotive, it has electric drive, in the form of traction motors
driving the axles and controlled with electronic controls. It also has many of the same
auxiliary systems for cooling, lighting, heating and braking power for the train. It can
be operated by the same drivers. The generating station consists of a large diesel engine
coupled to an alternator producing the necessary electricity. A 1000 gallons fuel tank is
also essential. Diesel engine itself not be able to pull train because there should large
number of gear transmission and friction loses will be present there, so it impossible to
run train without electric drive, in the form of traction motors.
Forman got me the information the different type of engine used in the shop.
Locomotives Use by Pakistan Railway
ES43ACI Engine:
This locomotive made by USA company General electric (GE). This locomotive is
design for harsh and high ambient temperature of Pakistan. This is bored gauge
locomotive and equipment with a v type 12 cylinder 4563 HP GE engine for high

34
optimal fuel efficiency. It has an 8000
litters high speed diesel tank is capable for
long distance route at the speed of 120
KPH. This locomotive has fully self-
loaded capability, a CCB break system, air
conditioning operated cab, additional
cooling and propulsion system capacity
and offer extensive service intervals.
EMD Engine:
The EMD 645 is a family of diesel engines
that was designed and manufactured by the Electro-Motive Division of General Motors.
While the 645 series was intended primarily for locomotive, marine and stationary
engine use, one 16-cylinder v type engine.
ENGINE CONFIGURATION:
Configuration 450 V Type, V16 Cylinder Diesel Engine
Displacement
5,160 to 12,900 cu in (84.6 to 211.4 L)
645 cu in (10.6 L) per Cylinder
Cylinder Bore 9+1/16 in (230mm)
Piston Stroke 10 in (254mm)
Valve Train
Intake Ports in Each Cylinder Liner, 4 Exhaust Valves in
Each Cylinder Head
Compression Ratio 14.5:1
Rpm Range Idle 200 RPM
Turbo Charger Single, Clutch Drive
Fuel System Unit Injector
Oil System Forced Lubrication System, Wet Sump
Cooling System Liquid cooled
Power Output 750 to 4,200 hp (560 to 3130KW)
Firing Order 1,8,9,16,3,6,11,14,4,5,12,13,2,7,10,15
Figure 24- Locomotive Engine

35
Classification of Railways Locomotives
Pakistan railways classified their locomotives in H.P (horse power) and every
locomotive is called on their own code numbers given by P.R. Detail of locomotives
with their numbers are following.
3000 H.P V-Type 16 Cylinders Locomotives:
• 8200 two stroke engine
2000 H.P V-Type 12 Cylinders Locomotives:
• 5001 four stroke engine
1200 H.P V-Type 6 Cylinders Locomotive:
1200 H.P V-type 6 cylinders locomotive (3700 four stroke) 950 H.P V-type 6
cylinders locomotive (3400 four stroke) Note: 2000/3000 H.P locomotive is mostly
using for passenger coach. It can easily pull more than 20 passenger coaches and more
than 100 cargo carriages. Where 1200/950 H.P locomotive is mostly using for shunting
and transporting of crane in emergency situation e.g. derail, accident and other needs.
Compression ratio: 16:1, Displacement per cylinder: 11.8 L (726 in3), Cylinder bore:
22.86 cm (9.003 inches), Cylinder
stroke: 28.95 cm (11.4 inches), Full speed: 915 rpm, Normal idle speed: 278 rpm
Displacement of 2000 H.P is 8712 in38c Displacement of 3000 H.P is 11616 in 3.8
these Locomotives are used in Pakistan railway.
List of Safety Devices in Working Order:
• Low Water Shutdown Device
• Low water Level Switch (LWLS)

36
• Low Lube Oil Shutdown Device
• Temperature Switch (ETP1)
• Temperature Switch (ETP2)
• Filter Clog Indicator (Vacuum Switch)
• Locomotive Over Speed
• Engine Over Speed
• Emergency Fuel Cut Off Switch
• Hot Engine
• Axle Alternator
• Radar Transceiver
• Event Recorder (Black Box)
• Sensor Lube Oil
• Sensor Fuel Oil
• Sensor Air Box
• Sensor Speed Magnetic Pick Up (S.P.U)
• Traction Motor Safety Device
• Alternator Safety Devices
• Radiator Protection
• Vigilance Devices
Engine control
Diesel Engine Control Governor:
I observed the engine governor and understand
the Diesel engine Control Governor's primary
function is to maintain speed of the diesel
engine as called by the Throttle handle notch
setting in the lead locomotive controller.
Engine rpm is maintained under a full range of
loads. Ialso observed that the governor also
monitors the engine oil and water pressures,
and will modulate the load and engine speed Figure 25- Diesel Engine
Governor

37
or, if necessary, shut the engine down if either pressure should fall below present limits.
Intake manifold air pressure is also monitored and the locomotive control system and
the governor will limit the fuel available to the engine if the air pressure is below that
required for complete combustion.
Engine over Speed Shutdown:
Foreman told me that the engine over speeds (1196/1 204 rpm), the engine is shut down
automatically. After an over speed shutdown of the engine, move the etc. switch to start
reset the over speed mechanism and proceed to start the engine as described under
starting engine section of this publication. It over speeds again. Do not restart the
engine.
Locomotive over Speed:
When a locomotive exceeds the maximum permissible speed (122 kph), a Penalty brake
application is initiated until the train speed has been reduced sufficiently.
Central Pivot:
I visual inspected of central pivot according to the information. The centre pivot pin
joins the body with the bogie and transmits the tractive and braking forces on the bogies.
It is equipped with rubber silent block bushes which tend to centralize the bogies with
respect to the body and to some extent, control and damp the angular oscillations of the
bogies.
• Driver cabin
• Driver cabin consists of the following
parts
• Digital speedometer
• RPM meter
• Battery voltage
•
Figure 26- Speedo Meter

38
• Amperes and voltage meters which show the Current and voltage consumed by
electric motors
• Pressure gauges for the air brake system
• Speed control lever idler to 6 speed
• Reverse control lever
• Wireless phone range of 40 miles
• Main electrical panel
• Air conditioner and Heather
• Pneumatic horn and antenna for wireless
are mounted on the drive cabin.
Engine Control Unit:
I got the information from the worker about the Engine Control Unit (ECU). That
it is located in the Power Device Comportment (PDC). The ECU is responsible for ne
control of the diesel engine under a range of operating conditions. The ECU also
protects the diesel engine from severe damage through the use of over speed protection
and power reductions when required or commanded by the engine management system.
I noticed the major functions of the ECU include:
• Engine speed control
• Acceleration and deceleration rate limiting
• Maximum fuel limiting
• Engine mode control (cranking, running, shutdown, idle, stationary, stall and over
speed)
• Engine protection lover speed, overload, smoke, low oil pressure, and low water
pressure)
• Timing control
• Diagnostics.
I also observed that the ECU monitors and identifies certain engine operating
parameters, and if detected as being outside of normal alert the microcomputer system
to reduce the engine speed and/or alternator load/excitation. These operating parameters
Figure 27- Guages

39
Primarily relate to low water pressure, low oil pressure, and fuel over demand
conditions. The low-pressure indications will result in a series of notch/speed reductions
Until normal pressure levels resume. A fuel demand condition will result in the shedding
of load from the alternator (reduced excitation) until such time as fuel demand can be
managed by fuel delivery.

40
5. Foundry shop
I visited the foundry and in the foundry shop different types of parts are produced using
the casting process. After casting the work pieces are machined to convert them into
various parts according to part structure. According to my knowledge there are Various
types of furnaces are available in at the Loco shop of the railway industry to cast
different numbers of parts according to demand. Operations to be performed and time
to make that part are mentioned on work order. Operation are performed according to
the sequence mentioned on the work order.
The Foundry shop is divided into two parts:
 Brass Foundry
 Iron foundry
Figure 28- Foundary Shop

41
Parts prepared in a brass foundry
There are following parts are prepared in this shop
 Sliding door handle
 Upper birth handle
 Coat hook
 Window catcher
 Window stopper
 Window panel
 Glass stand
 Motor cover
Parts prepared in an 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
Figure 29- Parts Prepared In Brass Foundary
Figure 30- Parts in Iron Foundary

42
Casting:
In Foundry section, I observed Casting process in which a liquid material is usually
poured into a mould,
which contains a hollow
cavity of the desired
shape, and then allowed
to solidify. The
solidified part is also
known as a casting,
which is ejected or
broken out of the mould
to complete the process.
Casting materials are usually metals or various cold setting materials that cure after
mixing two or more components.
Casting process
Casting is the process of pouring molten metal into the previously made cavity to the
desired. I saw the process of casting by using molten metal in the bucket and pouring it
in the Shape and allow it to solidify
The following are the basic operations of the casting process
 Pattern Making
 Mould preparation
 Melting the metal
 Pour it into a previously made mould which confirms the shape of the desired
component.
Pattern:
I foundry shop, I observed that to make cavity pattern is used. Pattern is an element
used for making cavities in the mould, into which molten. Metal is poured to produce a
casting.
Requirements of a good pattern and pattern allowance.
Figure 31- Casting Process

43
 Secure the desired shape and size of the casting
 Simple in design, for ease of manufacture
 Cheap and readily available Light in mass and convenient to handle
 Have high strength
Different types of
patterns:
 Split or Parted Pattern
 Loose Piece Pattern
 Drawbacks
 Gated Patterns.
 Match Plate pattern
 Cope and Drag Pattern
 Sweep Patterns.
Mould preparation:
A mould is formed into the geometric shape of a desired part. Molten metal is then
poured into the mould, the mould holds this material in shape as it solidifies. A metal
casting is created. Although this seems rather simple, the manufacturing process of
metal casting is both a science and an art. First, moulds can be classified as either open
or closed. An open mould is a container, like a cup, that has only the shape of the desired
part. The molten material is poured directly into the mould cavity which is exposed to
the open environment.
Mould preparation:
Sand used in the moulding process
Different types of sand are use in brass and iron foundry
Figure 32- Pattern
Figure 33- Mould Preparation

44
Green sand mould:
A green sand mould is composed of a mixture of sand, clay, and water.
Dry sand mould:
Dry sand moulds are basically green sand moulds with 1% to 2% cereal flour and 1%
to 2% pitch.
Materials used in mould preparation
Silica sand, Binder, Additives, and water
Furnaces used in the foundry workshop
Different types of furnaces used in workshop
Tilting furnace
Forman told tilting furnance is used for Aluminium and brass materials to be melted in
this furnace
 Temperature of aluminium melting 550-600 F
 Temperature of brass melting 1050-1150 F
Figure 34- Tilting Furnance

1 Week & 1 Day Work Experience
45
6. Power Plant Shop
Power Plant Introduction
The power plant shop is located in carriage and wagon shop the diesel engine produces
mechanical energy by converting heat energy derived from the burning of fuel inside
the cylinder. For efficient burning of fuel, the availability of sufficient air in the proper
ratio is a prerequisite
In a naturally aspirated engine, during the suction stroke, air is sucked into the cylinder
from the atmosphere. The volume of air thus drawn into the cylinder through restricted
inlet valve passage, within a
limited time would also be
limited and at a pressure
slightly less than the
atmosphere. The availability of
less quantity of air of low
density inside the cylinder
would limit the scope of
burning of fuel. Hence
mechanical power produced in
the cylinder is also limited
An improvement in the naturally aspirated engines is the super-charged or pressure-
charged engines. During the suction stroke, pressurised stroke of high density is charged
into the cylinder through the open suction valve. Air of higher density containing more
oxygen will make it possible to inject more fuel into the same size of cylinders and
produce more power, by effectively burning it. A turbocharger, or turbo, is a gas
compressor used for the forced-induction of an internal combustion engine. Like a
supercharger, the purpose of a turbocharger is to increase the density of air entering the
engine to create more power. However, a turbocharger differs in that the compressor is
powered by a turbine driven by the engine's exhaust gases
Figure 35- Power Plant

46
Turbo Supercharger and its Working Principle
In power plant shop I gained a lot of information about the turbo charger working and
its principle. The exhaust gas discharge from all the cylinders accumulate in the
common exhaust manifold at the end of which, turbo- supercharger is fitted. The gas
under pressure there after enters the turbo- supercharger through the torpedo shaped bell
mouth connector and then passes
through the fixed nozzle ring. Then
it is directed on the turbine blades at
increased pressure and at the most
suitable angle to achieve rotary
motion of the turbine at maximum
efficiency. After rotating the
turbine, the exhaust gas goes out to
the atmosphere through the exhaust
chimney. The turbine has a
centrifugal blower mounted at the
other end of the same shaft and the
rotation of the turbine drives the blower at the same speed. The blower connected to the
atmosphere through a set of oil bath filters sucks air from the atmosphere, and delivers
at higher velocity. The air then passes through the diffuser inside the turbo-
supercharger, where the velocity is diffused to increase the pressure of air before it is
delivered from the turbo-supercharger.
Pressurizing air increases its density, but due to compression heat develops. It causes
expansion and reduces the density. This affects supply of high-density air to the engine.
To take care of this, air is passed through a heat exchanger known as an after cooler.
The after cooler is a radiator, where cooling water of lower temperature is circulated
through the tubes, and around the tubes air passes. The heat in the air is thus transferred
to the cooling water and air regains its lost density. From the after cooler air goes to a
common inlet manifold connected to each cylinder head. In the suction stroke as soon
as the inlet valve opens the booster air of higher pressure density rushes into the cylinder
completing the process of supercharging.
Figure 36- Turbo Charger

47
Main Components
Turbo- supercharger consists of the following main components.
 Gas inlet casing.
 Turbine casing.
 Intermediate casing
 Blower casing with diffuser
 Rotor assembly with turbine and rotor on the same shaft
Rotor Assembly
The rotor assembly consists of a rotor shaft, rotor
blades, thrust collar, impeller, inducer, centre
studs, nosepiece, locknut etc. assembled. The
rotor blades are fitted into fir tree slots, and locked
by tab lock washers. This is a dynamically
balanced component, as this has a very high
rotational speed.
Lubricating System
I observed that one branch line from the lubricating system of the engine is connected to the
turbo-supercharger. Oil from the lube oils system circulated through the turbo-supercharger for
lubrication of its bearings. After the lubrication is over, the oil returns to the lube oil system
through a return pipe. Oil seals are provided on both the turbine and blower ends of the bearings
to prevent oil leakage to the blower or the turbine housing.
Cooling System
The cooling system is integral to the water cooling system of the engine. Circulation of water
takes place through the intermediate casing and the turbine casing, which are in contact with
hot exhaust gases. The cooling water after being circulated through the turbo- supercharger
returns to the cooling system of the locomotive.

1 Week & 1 day Work Experience
48
7. Heat Treatment Shop C&W Shop
In this shop, I gathered the information that how to prepared piece by using different
heat treatment processes the operation
involving the heating and cooling of a
metal or an alloy in the solid state to
obtain certain desirable properties
without change composition. About my
knowledge the process of heat treatment
is carried out to change the grain size, to
modify the structure of the material, and
to relieve the stresses set up the material
after hot or cold working.
 The heat treatment is done to improve the machinability.
 To improve magnetic and electrical properties.
 To increase resistance to wear, heat corrosion and much more reason.
Heat treatment consists of heating the metal near or above its critical temperature, held
for a particular time that finally cooling the metal in some medium which may be air,
water, brine, or molten salts. The heat treatment process includes annealing, case
hardening, tempering, normalizing and quenching, nitriding, cyaniding, etc.
Steps in heat treating operation
I observed by different information that few step are used in heat treatment process
that is given below:
Loading:
 Cleaning
 Pre-cash with coalescence
 De-phosphate system
 Spray rinse
Figure 37- Heat Treatment Shop

49
Heating:
 Pre-heating
 Heating
 Soak & diffusion
 Pre-cooling
Cooling:
 Quenching
 Post wash
Finishing:
 Tempering
 Surface coating
 unloading
Types of Heat Treatment Processes
Eight different types of heat treatment processes are as follows:
 Annealing
 Normalizing
 hardening
 Tempering
 Nitriding
 Cyaniding
 Carburizing
 Flame Hardening

50
Annealing:
Annealing is a heat treatment process that alters the microstructure of a material to
change its mechanical or electrical
properties. Typically, in steels,
annealing is used to reduce
hardness, increase ductility, and
help eliminate internal stresses.
Annealing is a generic term and
may refer to subcritical,
intermediate, or full annealing in a
variety of atmospheres. Annealing
is one of the most important
processes of heat treatment. It is
one of the most widely used operations in the heat treatment of iron and steel and is
defined as the softening process.
Heating from 30 - 50°C above the upper critical temperature and cooling it at a very
slow rate by seeking it the furnace. The main aim of annealing is to make steel more
ductile and malleable and to remove internal stresses. This process makes the steel soft
so that it can be easily machined.
Normalizing:
Normalizing aims to give the steel a
uniform and fine-grained structure.
The process is used to obtain a
predictable microstructure and an
assurance of the steel’s mechanical
properties. The main aim of
normalizing is to remove the internal
stresses developed after the cold
working process. In this, steel is
heated 30 - 50°C above its upper
Figure 38- Annealing Process
Figure 39- Normalizing

51
critical temperature and cooled in the air.
During normalizing, the material is heated to a temperature approximately equivalent
to the hardening temperature (800-920°C). At this temperature, new austenitic grains
are formed. The austenitic grains are much smaller than the previous ferritic grains.
After heating and a short soaking time, the components are cooled freely in air (gas).
During cooling, new ferritic grains are formed with a further refined grain size.
Hardening:
Case hardening is the process of
hardening the surface of a metal by
infusing elements into the material’s
surface, forming a thin layer of harder
alloy.
Combined with a subsequent
hardening operation the desired
component properties can be varied to
suit the application. The main aim of
the hardening process is to make steel
hard and tough. In this process, steel is heated 30° - 40°C above the upper critical
temperature and then followed by continues cooling to room temperature by quenching
in water or oil. It is the opposite process of annealing.
Tempering:
Tempering is a low temperature heat treatment process normally performed after neutral
hardening, double hardening, atmospheric carburising, carbonitriding, or induction
hardening to reach a desired hardness/toughness ratio. When the hardening process
hardens a steel specimen, it becomes brittle and has high residual stress. It is an
operation used to modify the properties of steel hardened by quenching to increase its
usefulness.
Tempering or drawing results in a reduction of brittleness and removal of internal strains
caused during hardening. Steel must be tempered after the hardening process.
Figure 40- Hardening

52
The tempering is divided into three categories according to the usefulness of the steel
required.
 Low-temperature tempering.
 Medium temperature tempering.
 High-temperature tempering.
Case hardening or surface hardening:
The main aim of this process is to make the only external surface of steel hard and the
inner core soft. It is the process of carburisation i.e., saturating the surface layer of steel
with carbon, or some other process by which case is hardened and the core remains soft.

53
8. Roller Baring Shop C&W Shop
In Rollar Bearing shop, I understood the function and use of different bearing. And
disassembling and repairing and servicing the bearing.
Roller Bearings:
Roller bearings also known as rolling-element bearings are similar to ball bearings in
that they are designed to carry a load while minimizing friction.
Rolling bearings support and guide rotating or oscillating machine elements – such as
shafts, axles or wheels – and transfer loads between machine components. They provide
high precision and low friction and
therefore enable high rotational
speeds while reducing noise, heat,
energy consumption, and wear.
Roller bearings transmit loads using
cylinder rolling elements, rather than
balls, to maintain the separation
between moving parts of the bearing.
These versatile bearings can contain
Figure 41- Roller Bearing Shop
Figure 42- Bearing

54
single or multiple rows of rolling elements; multiple rows can significantly improve
radial load capacity.
Their applications are generally limited to low-speed operations. Many types of roller
bearings are self-aligning, and are easily able to overcome misalignment and mounting
issues cutting down on maintenance, repair, and labour needs.
Roller bearings come in a wide range of shapes and sizes and can be customized for
specialized situations. Also, the use of flanges, cages, and multiple bearing rows can
allow for higher performance to meet specific application needs.
Roller Bearing Types and Application
In this shop, I got the information about the different bearing are used. The description is
given below
1. Cylindrical Roller Bearings:
Cylindrical roller bearings are available in a wide range of designs, series, variants and
sizes. The main design differences are the number of roller rows and the inner/outer
ring flanges as well as cage designs and materials. The bearings can meet the challenges
of applications faced
with heavy radial loads
and high speeds.
Accommodating axial
displacement (except for
bearings with flanges on
both the inner and outer
rings), they offer high
stiffness, low friction,
and long service life.
Cylindrical roller
bearings are also
available in sealed or split designs. In sealed bearings, the rollers are protected from
contaminants, water, and dust, while providing lubricant retention and contaminant
exclusion. This provides lower friction and longer service life. Split bearings are
Figure 43- Cylindrical Bearing

55
intended primarily for bearing arrangements that are difficult to access, such as crank
shafts, where they simplify maintenance and replacements.
2. Spherical Roller Bearings:
These can carry heavy loads even when
dealing with misalignment and shaft
deflection. They can be designed to have
cylindrical or tapered bores for mounting
with or without a sleeve adapter. Available
with various internal clearances and retainer
options, spherical roller bearings can handle
axial loading in either direction as well as
heavy shock loads. These bearings are
available in bore dimensions ranging from
20 mm to 900 mm.
3. 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. Drawn cup styles allow for
high load capacities and large grease reservoirs while still offering a slim cross-section
design. These bearings are offered with inch or metric seals.
Figure 44- Spherical Bearing

56
4. Taper Roller Bearings:
Tapered Roller Bearings are designed to reduce friction and, in turn, reduce the heat
that can cause bearing structures to
fail. This bearing is used in many
industrial applications and is
optimal for those undergoing excess
loads bearings can support radial
and thrust loads. They can only
handle unidirectional axial loads, so
a second laterally reversed bearing is
required for counter-stay. Taper
roller bearings are available in inch
and metric sizes.
Bogie Frame:
The bogie frame is a solid ilded frame made by metal sheets and solid or cast
components. The frame is made of two longitudinal components connected by means
of two move-beams which additionally guide the brake gadgets. The various supports
which connect the distinct bogie additives are ilded to the body. The bogie frame rests
at the number one suspension spring devices and helps the vehicle body with the aid of
a bolster beam. The bolster beam is connected to the bogie frame via the secondary
suspension.
Suspension
I. Primary Suspension:
Primary suspension is carried out by way of two units of two steel coil springs (internal
and outside) laid out on the manage arm top component by a cantering disk and
adjustment shims, (if required). The suspension is likewise finished by using the
subsequent additives: A manipulate arm, fitted with dual-layer elastic joints, connecting
the axle bearing to the bogie body and transmitting, not stiffly, lateral, longitudinal and
part of the vertical forces; A vertical damper. Rubber elements separate the number one
Figure 45- Taper Bearing

57
suspension from the bogie to realise noise reduction. Stops and protections are installed
at the bogie frame for the lifting.
 Bogie frame
 Rubber disks
 Cantering disk
 Internal spring
 External spring
 Bump stop
 Shim
 Cantering disk
 Control Arm Lowerr
Part
 Plate
 Block
 Rubber joint
 Control Arm Upper Part
 Damper
II. Secondary Suspension:
The secondary suspension allows lateral and vertical displacements and bogie rotation
with respect to body whilst jogging through curves. It is carried out via spring packs
which sustain the bolster beam over the bogie frame. Every spring percent is made up
with the aid of an internal and an outside spring, installed and located through the
cantering discs. An anti-roll bar,
geared up on the bogie body,
realizes a constant, reduced
inclination coefficient during
jogging. The bogie body is
linked to the bolster beans via
two vertical dampers, a lateral
damper, 4 protection cables and
Figure 46- Primary Suspension
Figure 47- Secondary Suspension

58
the traction rods. The bogie body is likewise related to the coach frame via two yaw
dampers.
 Bolster beam
 Anti- roll bar
 internal spring
 Outside spring
 Centring disk
 Bogie body
 Vertical damper
 Lateral damper

2 Week 6 Days Work Experience
59
9. Motor Shop C&W Shop
The responsibility of motor shops in carriage and wagon is to repair and overhauling
cars, buses, trucks, forklifts lifter and cranes used for Pakistan railways.
In Motor shop, I observed the engine over hauling and repairing. This shop consists of
mainly two sections. And these engine detailed are given below.
Petrol section
In the petrol section automobile vehicles owned by the Pakistan railway are being
repaired and overhauled.
Diesel section
In the diesel section different types of buses, trucks, and other diesel vehicles like cranes
and forklifts are overhauled.
The Mazda Titan is a commercial truck produced by the Japanese automaker Mazda
since 1971. From the fourth generation onwards, the vehicle became a rebadged Isuzu
Elf truck.
The first Titan was presented in 1971, as a successor to the two-ton Mazda E2000. The
box-section chassis rails were unusual for the class. Receiving the chassis code "EXB",
the tilt-cab Titan retained the 2.5-liter "XA" diesel engine of the earlier E2000 without
Figure 48- Motor Shop

2 Week 6 Days Work Experience
60
any change. For heavier-duty usage, there was also the XB-engine Titan T2700: a 2.7
L (2,701 cc) diesel version with four more horsepower (81 PS or 60 kW). A 2.0-litre
petrol four-cylinder engine was also available. In 1977, the Titan underwent a minor
change and facelift. Along with a new grille and bumpers, the turn signals were bigger
and more squared off and incorporated vents for the cabin. Most obviously, the old
round "M" logo was replaced by the new corporate "MAZDA" logo.
The second generation was announced in October 1980. Engine capacity increased to
4052 cc with the introduction of the new, six-cylinder ZB diesel engine. 2.0, 2.5, and 3-
liter four-cylinder models were also available. This model also received a dual range
(ten-speed) transmission, marketed as the "Two Way Shift. “In 1982 the second
generation Mazda Parkway bus version was introduced, based on the new Titan.
The purpose of the fuel injection system is to deliver fuel into the engine cylinders,
while precisely controlling the injection timing, fuel atomization, and other parameters.
The main types of injection systems include pump-line-nozzle, unit injector, and
common rail. Modern injection systems reach very high injection
Figure 49- Diesel Engine

Final lab Report19AU006.pdf Supervised Industrial Training

Final lab Report19AU006.pdf Supervised Industrial Training

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