Final report(19AU012).pdf Supervised Industrial Training

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Industrial Training Report
Name : Shahzeb Akhtar
Class Roll No : 19AU012
Industrial Training Course : Supervised Industrial Training
Training Period : 16 Weeks
Training Organization : Pakistan Railway

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

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ACKNOWLEDGEMENT
I am very much grateful to the organization’s authority for taking the initiative for the
industrial training to upgrade my knowledge by placing me at Railway Pakistan. I owe
my thanks to several people who helped and support me during this training. I wish to
express my gratitude to the officials and other members of Railway Pakistan who
rendered their help during the period of my training. I express my sincere thanks to the
senior section engineer, who through his expert guidance helped me throughout the
course of this training. If it was not for his motivation and encouragement, I would not
have seen through this training course an honest course to the splendor of success.

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Table of Contents
ABSTRACT................................................................................................................................. 2
ACKNOWLEDGEMENT.............................................................................................................. 3
Chapter1: Backgrounds of the Pakistan Railway ..................................................................... 7
MISSION:.............................................................................................................................. 8
VISSION: ............................................................................................................................... 8
Mughalpura Workshop Area:............................................................................................... 9
ORGANIZATIONAL TRUCTURE:........................................................................................... 10
Chapter2: Schedule of Training & Duties, as a Trainee ......................................................... 11
Training Schedule............................................................................................................... 11
Duties as Trainee:............................................................................................................... 12
Chapter 3: WORKING EXPERIENCE ........................................................................................ 23
Week 1:.............................................................................................................................. 23
Week 2 ............................................................................................................................... 23
Week 3 ............................................................................................................................... 24
Week 4 ............................................................................................................................... 24
Week 5 ............................................................................................................................... 25
Week 6 ............................................................................................................................... 25
Week 7 ............................................................................................................................... 26
Week 8 ............................................................................................................................... 26
Week 9 ............................................................................................................................... 27
Week 10 ............................................................................................................................. 27
Week 11 ............................................................................................................................. 28
Week 12 ............................................................................................................................. 28
Week 13 ............................................................................................................................. 29
Week 14 ............................................................................................................................. 29
Week 15 ............................................................................................................................. 30
Week 16 ............................................................................................................................. 30
Week 17 ............................................................................................................................. 30
Chapter 4 Project Carried Out ............................................................................................... 31
Diesel Classified Repair Shop: ........................................................................................ 32
E & Dc Shop Loco Shop .................................................................................................. 39
Tool Shop Loco Shop...................................................................................................... 45
Diesel Rehibition Shop Loco Shop.................................................................................. 48

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Foundry Shop Loco Shop................................................................................................ 54
Power Plant Shop........................................................................................................... 60
Heat Tretment:............................................................................................................... 64
Roller Baring Shop:......................................................................................................... 65
Motor Shop C&W Shop.................................................................................................. 69
Central laboratory.............................................................................................................. 73
Chapter 5: Conclusion............................................................................................................ 74
Recommendation:.............................................................................................................. 74
Chapter6: Reference.............................................................................................................. 75
Appendix:............................................................................................................................... 76

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Table of Figure
Figure 1 INTRODUCTION......................................................................................... 7
Figure 2 diesel classified shop ................................................................................... 13
Figure 3 E & Dc shop ................................................................................................ 14
Figure 4 TOOL SHOP ............................................................................................... 15
Figure 5 Diesel Rehibition shop................................................................................. 16
Figure 6 Foundry shop ............................................................................................... 17
Figure 7 Power plant shop ......................................................................................... 18
Figure 8 Heat Treatment shop.................................................................................... 19
Figure 9 Roller Baring shop....................................................................................... 20
Figure 10 Motor Shop................................................................................................ 21
Figure 11 locomotive workshop................................................................................. 31
Figure 12 diesel classified repair shop....................................................................... 32
Figure 13 E & Dc shop .............................................................................................. 40
Figure 14 Grill machine ............................................................................................. 41
Figure 15capstan lath machine................................................................................... 42
Figure 16 Centre lath machine................................................................................... 42
Figure 17 Boring machine.......................................................................................... 43
Figure 18 Tool shop ................................................................................................... 46
Figure 19 Secondary suspension................................................................................ 53
Figure 20 Primary suspension.................................................................................... 54
Figure 21 Cupola furnace........................................................................................... 55
Figure 22 Tilting furnace ........................................................................................... 56
Figure 23 Rotary furnace ........................................................................................... 56
Figure 24 Carriage and wagon shop........................................................................... 60
Figure 25 Diesel Generator........................................................................................ 61
Figure 26 Screw coupling .......................................................................................... 65
Figure 27 Puller.......................................................................................................... 68
Figure 28 Bearing removing ...................................................................................... 69
Figure 29 Diesel Engine............................................................................................. 72

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Chapter1: Backgrounds of the Pakistan Railway
Figure 1 INTRODUCTION
Pakistan Railways is lifeline of the country. It is a national state - run transport service
running under the administration of Pakistani Government's “Ministry of Railways
".Pakistan Railways provides an important mode of transportation in the farthest
corners of the country and brings them closer for business, sightseeing and education
. It has been a great integrating force and forms the life line of the country by catering
to its needs for large scale movement of people and freight. It carries millions of
passengers and carries huge freight in throughout the Pakistan. Thus it is the cheapest
and safest mode of transportation throughout the Pakistan. Tough, Railway is the
cheapest and safest mode of transportation throughout the Pakistan. Still, Government
is not taking any interest to make some improvements in this industry. When Britain
closed the curtain on its empire and Pakistan was born in 1947, the country inherited

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thousands of miles of track and trains provided the mostly popular and affordable
transport for millions but instead of rising the condition of this industry is getting worse
day by day. Pakistan Railways is the national, state-owned railway company of
Pakistan. Founded in 1861 and headquartered in Lahore, it owns 7,791 kilometers
(4,841 miles) of track across Pakistan, stretching from to Karachi, offering both freight
and passengers services.
In 1855, during the British Raj, several railway companies began laying tracks and
operating in Sindh and Punjab. The country's railway system was originally a
patchwork of local rail lines operated by small, private companies, including the
Scinde Railway, Punjab Railway, Delhi Railway and Indus Flotilla. In 1870, the four
companies combined to form the Scinde, Punjab & Delhi Railway. Several other rail
lines were soon built, including the Indus Valley State Railway, Punjab Northern State
Railway, Sind–Sagar Railway, Sind Pishin State Railway, Trans–Baluchistan Railway
and Kandahar State Railway. These six companies merged with the Scinde, Punjab &
Delhi Railway to form the North Western State Railway in 1880.
MISSION:
To lead the public and private sector in the engineering disciplines including
Railways by providing highest quality and safety standards in an economical and
efficient manner.
VISSION:
To achieve excellence in Engineering Services with special emphasis on Railway
Sector and to become an international commercial company operating beyond
Pakistan's borders.

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Mughalpura Workshop Area:
Factory Area:
 Covered Area: 27acres
 Uncovered Area: 165 Acres
 Factory Area: 192 Acres
Staff Details:
 Skilled Staff 2893
 Semi-Skilled 587
 Unskilled Staff 246
Major Departments:
 Mechanical Department
 Electrical Department
 Store Department
 Civil Engineering Department

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Chapter2: Schedule of Training & Duties, as a Trainee
Training Schedule
The schedule of the training is give below.
SR.NO NAME OF SHOPS PERIOD OF TRAINING
1 Diesel Classified Repair Shop Loco 27-03-2023 to 15-04-2023
2 E & Dc Shop Loco Shop 16-04-2023 to 22-04-2023
3 Tool Shop Loco Shop 23-04-2023 to 01-05-2023
4 Diesel Rehibition Shop Loco Shop 02-05-2023 to 15-05-2023
5 Foundry Shop Loco Shop 16-05-2023 to 25-05-2023
6 Power Plant Shop C&W Shop 26-05-2023 to 10-06-2023
7 HEAT Treatment Shop C&W Shop 11-06-2023 to 18-06-2023
8 Roller Baring Shop C&W Shop 19-06-2023 to 29-06-2023
9 Motor Shop C&W Shop 30-06-2023 to 19-07-2023
10 Central Laboratory MGPR 20-07-2023 to 22-07-2023

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Duties as Trainee:
As A Trainee, We've To Observe The All Working Process At Different Sites Or
Working Spaces. Our Duties Are To Analyze The General Faults And Their Solutions
Including Time Management And Other Important Factors Which Affect The
Maintenance Process Of Any Working Site. These Factors Are The Following: To
Understand The Manufacturing And Repairing Of Rail Coaches And Wagons. To
Observe And Acquire Knowledge About Different Mechanisms Dealing With
Different Machines. To APPLY The Theoretical Technical Knowledge To Real
Industrial Applications. To Build Good Communication Skills With A Group Of
Workers And Learn Proper Behavior Of Corporate Life In The Industrial Sector.

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1. Diesel Classified Repair Shop Loco.
 Engine Overhauling
 Locomotive Maintenance
 Locomotive Repairing
 Locomotive Inspection and Testing
 Engine Checking
 Checking traction motor
 Separated bogie
 Wheel disassembly and assembly
 Suspension disassembly and assembly
Figure 2 diesel classified shop

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2. E & Dc Shop Loco Shop:
In This Shop section:
 Lath Section
 Milling Section
 Fitting Section
 Marking Section
 Grinding Section
Parts Prepared:
 Oil Seal
 Friction Plate discharge Valve
 Valve Guide
 Crankshaft
 Connecting Rod Bush
Figure 3 E & Dc shop

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3. Tool Shop Loco Shop:
Machines used in tool shop:
 Universal Milling Machine
 Horizontal Milling Machine
 Shaper Machine
 Lath Machine
Parts made in tool shop:
 Barth catcher
 Window lock Barth handle
 Finger plate
 Window staper
 Railway wood made logo
Figure 4 TOOL SHOP

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4. Diesel Rehibition Shop Loco Shop:
 Locomotive Overhauling
 Locomotive Tasting
 Locomotive Inspection
 Include Every Five Year Inspection
 Engine brake inspection
Figure 5 Diesel Rehibition shop

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5. Foundry Shop Loco Shop:
Furnace Use In Foundry Shop:
 Rotary Furnace
 Tilting Furnace
 Cupola Furnace
Foundry shop making to
 Leaded bronze
 Phosphorous bronze
 Metal brazing
Figure 6 Foundry shop

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6. Power Plant Shop C & W Shop:
 Diesel generator repair
 Diesel generator inspection
 Generator oil check
 Generator heat tasting
 Lubrication oil check
Figure 7 Power plant shop

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7. Heat Treatment Shop C & W SHOP:
Heat treatment method
 Annealing
 Hardening
 Normalizing
 Tempering
 Carburization
Heat treatment shop make to
 Brushes all type
 Pins
 Screw coupling
Figure 8 Heat Treatment shop

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8. Roller Baring Shop:
 Installation baring
 Baring repairing
 Baring inspection
 Check baring surface
 Baring lubricated
Figure 9 Roller Baring shop

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9. Motor Shop:
 Suspension Working
 Body Working
 Engine Assemble And Disassemble
 Engine Repair
 Oil Changing
Figure 10 Motor Shop

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10. Central laboratory:
In This Shop Machine Use
 Birnall Hardness Testing Machine
 Rockwell Hardness Testing Machine
 Universal Testing Machine
Lab Testing
 Simple collection
 Hardness check
 Metrial Testing
 Oil Test
 Water Test
 Fuel testing
 Grease Testing

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Chapter 3: WORKING EXPERIENCE
Week 1:
Diesel Classified Repair Shop Loco.
 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.
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.

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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.
Week 4
E & DC Shop
 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.

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Week 5
Tool Shop
 I went to Tool shop and submitted my schedule. And foreman gave the
 I observed the different operations performed in the lathe machine operations.
 I observed the different operations performed in the fitting machine section.
clerk office.
Week 6
Rehabilitation shop
 I went to Rehabilitation shop and submitted my schedule. And foreman gave
the introduction about 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.

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Week 7
 Visual inspection of engine and train body.
 Visual inspection of damage of bogie.
 Visual inspection of solving procedure.
 Study of locomotive beam and types used in advance locomotive.
 Visual study separating accidental locomotive and its rehabilitation.
 Visual study of basic operation of locomotive.
Week 8
clerk office in rehabilitation shop.
 I went to foundry shop and submitted my schedule. And foreman gave the
 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.

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Week 9
 Visual inspection of copper furnace and their material made.
 I studied melting temperature of different materials.
 I checked the hardness of material that made in this shop.
clerk office in Foundry shop.
 I went to Power plant shop and submitted my schedule. And foreman gave the
 Inspection of Cummins generator used in power van.
Week 10
Power Plant shop
 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.

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Week 11
 Inspection of coupler connection in power van.
 Learned the working principle of coupler.
 Inspection of wiring in power van.
 I learned the difference between Chinese and German power van.
 I learned the safety factor of power plant shop.
I compiled my attendance sheet by signing it from foreman and submitted to clerk
office in Power plant shop
Week 12
Heat Treatment shop
 I went to Heat treatment shop and submitted my schedule. And foreman gave
the introduction about 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.
clerk office in Heat treatment shop.

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Week 13
Roller Bearing Shop
 I Went To Roller Bearing Shop And Submitted My Schedule. And Foreman
Gave The Introduction About 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.
Week 14
 I learned the safety factor of roller bearing shop.
clerk office in roller bearing shop.

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Week 15
Motor shop
 I went to motor shop and submitted my schedule. And foreman gave the
 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.
Week 16
 I learned how to adjust piston rings in diesel engine.
 I learned how to adjust the timing of diesel engine.
 I gained information of how to assemble the diesel engine after over hauling.
 I got information that how to inspect the diesel engine after over hauling.
 I learned the basic maintenance of diesel engine.
 I inspected the suspension of buses in motor shop.
Week 17
 In this shop, I inspected the electrical and brake system.
 I learned the safety factor of motor shop.
clerk office in motor shop.

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Chapter 4 Project Carried Out
LOCOMOTIVE WORKS:
Pakistan locomotive workshop Mughalpura Lahore was built in 1912. In the
locomotive workshop, all the maintenance departments work for Pakistan Railways
locomotives restoration. Most of them were HGMU30 EMD locomotives and others
were ZCU30 Made in China locomotives, all the process of maintenance is being done
by locals as a first come first serve policy.
Figure 11 locomotive workshop
These are the following shops in which we have worked in Locomotive works:
 Diesel Classified Repair Shop
 Tool Shop
 E& Dc Shop
 Diesel Rehibition Shop
 Foundry Shop
 Diesel Classified Repair Shop

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Diesel Classified Repair Shop:
Main This Workshop Was About The Repairing Mending And Overhauling Of An
Engine DIESEL Engine Along It Its Corresponding System. As Our Project With
China Also Contained The Over Allying Procedure Of Their Engine Along With Bring
New Ones. China Engine Need A Complete Over Allying Procedure At Last Three
Years In Oder To Meet The Proper Running Condition Of The Engine.
Figure 12 diesel classified repair shop
Parts of Locomotive
There Are Several Parts Of A Locomotive As Given Below And Demonstrated.
 Diesel Engine
 Lubricating System
 Main Generator
 Battery

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 Cooling System
 Air Compressor
 Compressed Reservoir
 Sandbox
 Radiator
 Air Filter
 Fuel Tank
 Dynamic Brake
 Driver Cab
Reading Constraints In The Cabin Of Locomotive
Driver Of Locomotive Notes The Following Reading To Ensure The Proper Working
Of The Train.
 Pressure Gage (Brake)
 Pressure Gage (Cylinder)
 Status Indicator
 Water Level Is Too Low
 Diesel Engine Alarming
 Computer Alarming
 Self Load
 Brake Pipe Pressure Is Too Low
 Compressor Is Running
 Brake Alarming
 Sliding Of Wheel
 Engine Speed
 Main Generator Current
 Main Generator Voltage
Locomotive Inspection and Its Maintenance Schedule
Maintenance of a locomotive is a complete job. Here is a table in which is a complete
taken to complete and the schedule of its inspection time taken to complete and the
parameter which are inspected during this process.

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Inspection Schedule Time Of Completion
A-Schedule (After Every Trip) 1 hrs.
B- Schedule (Monthly) 2 hrs.
C- Schedule (Every Three Monthly) 8 hrs.
D- Schedule (Every Six Monthly) 8 hrs.
E- Schedule (Every Nine Monthly) 8 hrs.
F- Schedule (Annual) 16 hrs.
Inspection parameters:
A-schedule
 Fuel oil & lube check
 Expresser discharge valve
 Flexible coupling bubbles
 Turbo run down test
 Record condition of wheel by star gauge
 Record oil level in the axle cap for suspension bearing
B-Schedule
 All the Works Done In T - 2 Schedule.
 All Cylinder Head Valve Loch Check.
 Sump Examination.
 Main Bearing Temperature Checked
 Expresser Valve Checked.
 Wick Pad Changed.
 Lube Oil Filter Changed.
 Strainer Cleaned.
 Expresser Oil Changed.

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Project: Top Desk Inspection
One Of The Most Common Rebuild Mistakes Is Failing To Inspect The Cylinder
Block Properly. Skipping This Step Can Lead To Premature Cylinder Head Gasket
Failure As Well As Block Damage , And It's Especially Important If You're On Your
Second Or Third Overhaul Or Have A High - Mileage Engine . Check The Top
Condition
 Remove The Cylinder Head Spacer Plate And Liners .
 Thoroughly Clean The Block . Make Sure No Debris Gets In The Casting
Holes , Which Could Contaminate The Cooling And Lubrication Systems .
 Check And Clean All Bolt Holes. Again, Ensure There's No Debris Or Foreign
Material Or You Won't Get Proper Torque When Replacing The Cylinder Head
.
 Check The Deck Surface For Straightness From Corner To Corner And
Between Cylinders .
 Look for Erosion and Cracks Around The Cylinder Liner Holes . If Your Block
Is Clean , Straight And Free Of Cracks Or Erosion , You're Ready For Step
Two . If Not , You'll need To Perform A Counter bore Cut First . Specs Are
Available On Sis.Cat.Com Or You Can Ask Your Local Authorized Cat Dealer
, Who Can Walk You Through Your Repair Options If You Can't Salvage The
Block.
Project: Lower Counter Bore Inspection
Next Up Is Inspecting The Engine Liners And Lower Counter Bore.
 Remove The Liners , Using A Proper Liner Removal Tool Not A Hammer.
 Inspect The Liner Surfaces For Erosion Or Cavitation .
 Check The Lower Counted bore Surface For Pitting And Erosion , Which
Usually Develop Near The Lower Liner Seal . If There's No Pitting Or Erosion
, Move To Step Three . Otherwise , Epoxy Or Machine The Area To Smooth

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Out The Surface , Which Will Help Prevent Leaks Into The Oil Pan And
Excessive Liner Movement .
Project: Liner Projection Measurement
The Final Step Before Starting Your Rebuild Is Measuring Liner Projection How Far
The Liner Extends Above The Spacer Plate On Top Of The Cylinder Block. If It's Not
Correct The Question Isn't If Your Head Gasket Will Fail But When.
 Put In A New Spacer Plate And Spacer Plate Gasket And Set In The Cylinder
Liners Without Seals
 . Set Up Your Liner Projection Tool (You Can Get One From Your Authorized
Cat Dealer) And Zero Out The Dial Indicator Along The Liner Flange.
 Check Projection in Four Areas Around The Liner. Measurements Can Vary
From Left To Right And Front To Back, And Allowable Variations Differ For
New, Cat Remain And Previously Counter Bored Blocks. All Specs Are
Available On Sis.Cat.Com Or From Your Cat Dealer.
.
Hand On Silk Acquired
 Learn To Locomotive Overhauling
 Learn To Locomotive Inspection
 Brake Inspection
 Separation To Wheel
 Separation To Taration Motor
 Locomotive Assembly And Disassembly
Problems Encountered
 Engine over heat
 Engine oil leakage.
Problems solving process
 Check the cooling system
 Check the oil leakage
 Maintain the problem
Supervisory WORKS
 Manage In The Workflow In The Workshop

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 Guidance Provide To Workshop Worker’s.
 Creating and Managing Team Schedules.
 Reporting To HR and Senior Management.
 Evaluating Performance and Providing Feedback.
 Helping To Resole Employe Issues and Disputes.
Improve productivity
 Encourage learning opportunities
 Provide employee with technology
 Strengthen communication protocols
 Proactive employee
 Good working condition
 Tool and equipment to raise productivity.
SAFETY AT WORK
 Keep open your eyes
 All-time activeness
 Wear shoes
 Wear safety helmet
 Don’t use lose clothing
 Focus on work.
 Avoid to locomotive heating parts.
 Don’t wear lose clothes.
 Wear safety shoes.
 Wear safety helmet before work.

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Project: Locomotive frames
For locomotive designed with a main frame all the loads from the weight of
installed equipment as well as traction and braking forces and dynamic and impact
loads are received carried or born by the strong structural design of the main frame.
Such Locomotive Are Relatively Easy To Manufacture And Repair But They Have
A Much Greater Consumption Of Material The Extra Weight Of Which Must Be
Considered In The Design So Far As The Axle Load Is Concerned.
In Addition the Main Frame Must Be Constructed With a Longitudinal Camber
So That The Frame Does Not The Sag When All Of The Equipment And Body Is
Placed On To The Frame.
The locomotive frames the cover locomotive engine.
Locomotive frame can be divided into three groups according to the structural
design of the main bearing element of the frames.
 Centre beam design where loads and stresses are primarily carried by
several centrally placed longitudinal beam running the full length of the
locomotive.
 Contour beam design where load and stress are primarily carried by
external beam fully encompassing the frame perimeter or outer contour.
 Combined.
Combined Frame
 In Combined Frames Loads And Stresses Are Distributed To Be
Taken By The Outer And Inner Beams.
 In All Three Main Frame Types Cable Conduits Can Be Installed
Internally Along The Main Beams Or Other Parts Of The Frame In
Order To Accommodate The Mounting Of Electric Cables And Wires
As Well As Piping Lines For Pneumatic Air Brake Or Hydraulic
Systems Of The Locomotive .

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Contour Frame
 In The Contour Beam Design Approach All Traction And Braking Loads Are
Reacted By External Beams Of The Main Frame.
 This Design Is Very Similar To A Ladder Frame Design But With Structural
Headstocks At Each End Of The Locomotive Providing The Frame With A
Fully Enclosed Outer Contour.
Centre Frame
 In The Centre Beam Design The Main Longitudinal Beams Which React
With All Traction And Braking Loads Are Located Towards The Centerline
Of The Frame.
 In Modern Locomotives It Is Common To Use Beams With Rectangular Or
Channel Cross Sectional Shapes Interconnected By Transverse Cross Beams
And Bulkheads.
E & Dc Shop Loco Shop
Machining of electrical and diesel components done in this shop. This shop has 6
different sections. All sections work together. The sections of this shop shown
below:
• Lath section
• Milling section
• Fitting section
• Marking section
• Grinding section

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Figure 13 E & Dc shop
In This Shop 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
• Con Rod
• Connecting Rod Bush
• Crank Shaft
• All Types of Bushes
• Crank Shaft OF Compressor

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Drill Machine
A Drilling Machine, Also Called A Drill Press, Is A Powerful Tool Used To Cut
A Round Hole Into Or Through Metal, Plastic, Wood, Or Other Solid Materials
Through Turning And Advancing Rotary Drill Bits Into A Work piece. This
Drilling Cutting Tool Is Held In The Drill Press By A Chuck And Fed Into The
Work At Variable Speeds. The Speed And Feed Should Be Set Properly And
Coolant Needs To Be Provided For The Desired Finished Part. This Machine
Use in E &Dc Shop. The Drilling Machine Can Not Only Be Applied In the
Drilling Process, But Also Useful For Many Other Machining Operations. There
Are Various Operations Can Be Performed On A Drilling Machine, Such As
Plane Drilling, Step Drilling, Core Drilling, Boring, Counter Boring, Reaming,
Countersinking, Spot Facing, Tapping, And Trepanning.
Figure 14 Grill machine
Capstan Lathe Machine
A Capstan Lathe Is A Milling Machine Used To Create The Same Parts Over And
Over Again. The Cutting Bits Are Mounted On A Rotatable Turret Known As A
Capstan, Which Allows The User To Quickly Change The Orientation Of The Bits For
Cutting Without Having To Take Off The First Bit And Then Mount The Second . A

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Piece Of Raw Material, Sometimes Known As A Blank Is Mounted Into The Capstan
Lathe And Is Then Spun At High Speed. The Cutting Tools, Sometimes Known As
Knives, Are Then Used To Cut Into The Blank To Create A New Shape Or Design.
Figure 15capstan lath machine
Centre Lath Machine
The Centre Lathe is used to manufacture cylindrical shape 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.
Figure 16 Centre lath machine

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Boring Machine
Boring Machine Device For Producing Smooth And Accurate Holes In A Work piece
By Enlarging Existing Holes With A Bore, Which May Bear A Single Cutting Tip Of
Steel Cemented Carbide Or Diamond Or May Be A Small Grinding Wheel. Single -
Point Tools Gripped In A Boring Head Attached To A Rotating Spindle, Are Moved
Circularly Against The Sides Of The Existing Holes. The Diameter Of The Hole Swept
Out By The Tool Is Controlled By Adjustment Of The Boring Head.
Figure 17 Boring machine
Project: oil seal
The Production Process Of The Oil Seal Is basically Composed Of The Following
Six Section.
 Rubber Preparation
 Mold Preparation
 Skeleton Preparation
 Spring preparation
 Product Vulcanization Forming
 Processing Assembly Section

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Rubber Preparation Section
THE Process Of This Section Are As Follow.
 RAW MATERIAL
 Factory inspection
 Batching
 Mixing.
 Filtering.
 Adding vulcanizing.
 Rubber material inspection
 Performing
Mold preparation section.
 Oil seal mold processing procedures.
 Usually the billet is pressed to eliminate its internal stress and then tempered
heat treatment some time cavity surface treatment according to the need of the
mold such as surface or for Harding plat.
Skeleton preparation section
Spring preparation section.
Vulcanization molding section.
Processing assembly section.
Hand On Sill Acquired
 Make to oil seal
 Work on Drilling
 Work on lath machine
 Work on boring machine
 Make to bolts shapes.
 Make to pins.
 Machine Is To Not Provide To Perfect Working.
 Machine Condition Is Not Good

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 Electric System Is Not Good
 Not Follow To Safety
Problem Solving Process
 Focus on work
 Machine maintenance
 Machine proper care
 Proper giving light in shop.
Improve productivity
 Encourage learning opportunities
 Provide employee with technology
 Strengthen communication protocols
 Proactive employee
 Good working condition
 Tool and equipment to raise productivity
Safety at Work
 Keep Your Workshop Clean
 Vision Protection
 Avoid to moving machine parts.
 Please Read The Book
 Keep Tools And Equipment
 Dress For The Occasion
 Avoid To Electric System
 Avoid Unnecessary Distraction
 Don’t use lose clothes.
Tool Shop Loco Shop
The Tool Shop in the Shop of Loco Shop. A Machine Tool Is A Machine For Shaping
Or Machining Metal Or Other Rigid Materials, Usually By Cutting, Boring, Grinding,
Shearing, Or Other Forms Of Deformation. Machine Tools Employ Some Sort Of Tool
That Does The Cutting Or Shaping.

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Figure 18 Tool shop
In This Shop Prepare The Tools. All Machine Tools Have Some Means Of
Constraining The Work Piece And Providing A Guided Movement Of The Parts Of
The Machine. In This Shop Manufacturing Of All Tools Took Place Which Is Being
Used All Over The Railway Workshops For So Many Machining Operations. This
Shop Has 6 Different Sections. These Sections Work Together And Made Different
Tools.
The Sections Are Shown Below:
• Fitting Section
• Press Tool & Gauges Section
• Die Sinking Section
• Lath Section

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• Milling Section
• Grinding Section
The Various Types Of Cutting Tool Materials Are Used In Tools To Remove Metal
From The Work Piece. Generally, The Tool Must Be Harder Than The Work Material.
The Selection Of Tool Material Depends Upon Various Factor. They Are:
• Design of Tool
• Production Volume
• Rigidity and Condition of the Machine Tool
• Physical and Chemical Properties of Job Materials.
Project: install the window lock
 First of all we got a lock.
 And after the the help of screw remove the old window lock.
 Clean the window surfaces.
 Install the new lock in window.
 Proper fitting to window lock in window.
 Putt the bolts in window lock surface.
 After bolts install check the window lock strong.
Hand On Silk Acquired
 Perform Work On Milling Machine
 Perform Work On Lath Machine
 Perform Work On Shaper Machine
 Required to machine reparing
 Tool surface is not good

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 Need to machine lubrication
 Proper Information About To Machine
 Not to provide proper give information.
 Give To Good Electric System
Safety At Work
 Keep Open Your Eye With Activeness.
 Avoid To Machine Moving Parts.
 Wear Ti Safety Gloves.
 Keep The Work Place Clean.
 Don’t Try To Stop Machine With Your Hands.
 Use The Appropriate Tools For The Work.
 Be CARE Full Over Head wear The Helmet during Welding.
 Wear safety gloves.
Diesel Rehibition Shop Loco Shop
Diesel Classified Shop Deals with The Repairing And Maintenance Of The Engine.
The Responsibility Of Diesel Classified Work Shop Is Overhauling Of All Locomotive
Of Pakistan Railway Every Five Year.
Power Assembly Section:
In Power Assembly Section, 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 9.003 “And Chrome Coated
Internally. Aluminum Made Piston Has 08.980”
Nozzle & Fuel Injection Pump Section:
In This Section , Injector Nozzle Is Tested On Nozzle Testing Machine By Applying
The 4050 Psi Pressure Of Diesel Spray , It Will Pass Through 9 Orifices Of Nozzle ,

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If There Is Any Blockage So It Will Be Corrected By Valve Seat Adjustment . Fuel
Injection Pump Is Also Calibrated On Calibrating Machine.
Electrical Section:
Electrical Section Deal With 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:
Air Compressors Of Locomotives Are Repaired Or Overhauled Here, 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 H.P. Locomotives. Where 3 Cylinders For 70 Psi Air Pressure And 3
Cylinders For 22 Lb .Inch Vacuum 6CD3UC Compressor.
VARIOUS TESTS TAKEN IN DIESEL LOCOMOTIVE
The Following Tests Are Being Conducted In the Diesel Locomotive To Check
Whether The Different Major Operative Parameters Are Working Properly Or Not
Project: Orifice Test:
Orifice Test Is Conducted To Ascertain The Efficiency To Be At Proper Optimized
Position Of The Fuel Feed System By Simulating The Full Load Condition. The
Procedure Of Testing Is As Under
 An Orifice Plate Of 1 / 8th “Is Fitted In The System Before Regulating Valve
During The Test A Container To Be Placed Under The Orifice To Collect The
Oil That Would Leak Through It The Fuel Booster Pump To Be Switched ON
For 60 Seconds.
 The Rate Of Leakage Should Be About 9 Liters / Min Through The Orifice
(With The Engine In Stopped Condition ) The System Should Be Able To

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Maintain 3.7 To 3.8 Kg / Cm2 Pressure With This Rate Of Leakage, Which
Simulates Approximately The Full Load Consumption By The Engine .
 In The Event Of Drop In Pressure, The Rate Of Leakage Would Also Be Less
Indicating Some Defect In The System Reducing Its Efficiency To Meet The
Full Requirement Of Fuel During Peak Load.
Project: Nozzle Testing
Spray Pattern:
Spray Of Fuel Should Be Properly Atomized And Uniform Through All The 9 Holes
Of The Nozzle.
 This Can Be Judged With An Impression Taken On A Blotting Paper The
Impression Of The Spray Pattern If Symmetrical ,
 Then The Nozzles Are In Proper Working Condition Opening Pressure: A
Very Minimum Portion Of The Oil Inside The Nozzle Passes Through The
Clearance Between The Pump, The Tester Handle Slowly And Record The
Opening Pressure.
 The Opening Pressure For New And Holder Should Be 1900 4050 Psi And
Rework And Holder Be 1700-1800 Psi If The Pressure Is Down To 3600 Psi
The Needs Replacement.
 Shies Are Being Used Into crease decrease The Spray Pressure.
 Norrle Chatter: The Chattering Sound Sort Of Cracking Noise Created Due
To Free Movement Of Nozzle Valve Inside The Valve Body. It Should Be
Proper Dribbling Or Tightness Of Valve Seat. There Should Be No Loss
Drop Of Face Coming Out Of The Nozzle Before Or After The Injection .The
Dribbling Can Be Checked By Having Injectors Manually Done Couple Of
Times Quickly And Check Whether The Nozzle Dip Is Dry Or Leaky. Raising
The Pressure And Holding It For 10 Second May Also Give Clear Ides Of
The Nozzle Dribbling. The Dribbling May Occur Due To Improper Pressure
Setting Or Direct Stick Up Between The Valve And Valve Seat Or Improper
Contact Between Valve And Valve Seat Area Or Valve Sticking Inside The
Valve Body

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 Nozzle Leak Rate: A Very Minimum Portion Of The Oil Inside The Nozzle
Passes Through The Clearance Between The Valve And Valve Body For
Circulatio , For Lubrication Purpose Excess Clearance May Cause Excess
Leak Off Thus Reducing The Amount Of Feel Actually Injected . Operate
The Test Handle To Attain 3500 Psi And Allow The Pressure To Drop Up To
1000 Psi , The Time Taken Is Known As Leak Off Rate And Is 19 Seconds
Per Nozzle ( New ) And 6 Seconds For Used Or Reconditioned Nozzle.
Project: Dry Run Test
This test conducted to check all rack position without moving the engine. The
procedure is as follows:
 Battery knife switch is put on close fuel pump , battery , control breakers on
control panel
 Close on both control stands etc. put in run position ( ck - 1 & ck - 2 also
dislocated by paper or wooden piece ) . Test to be done an mcbg (
microprocessor controlled based governor ) by selecting dry ran test mode
 Rack displacement is checked on display without fuel and with fuel with the
help of fuel booster pump stop & start. As per demand reset of racks are done
by adjustment.
Hydraulic Testing:
Hydraulic Test Is Being Conducted To Check Leakage In The Cylinder Head
.Followings Are The Of Hydraulic Testing The Cylinder Heads Are To Be Loaded At
Hydraulic Test Stand And Make Connection For Water It And Outlet And Check The
Water Temperature , It Should Be In Between 70-80 ° C Opon The Inlet And Outlet
Valve And Start The Water Pump , Check The Water Pressure Which Should Be 5 Kg
/ Cm.
 The Heated Water To Be Circulated Through Cylinder Head For Minimum 15
Minutes For Preheating The Cylinder Head Before Testing The Cylinder Head
For Leakages .

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 And Any Internal Cracks Check The Cylinder Head For Nozzle Sleeve Crack
And Body Crack , Leakage From Dummies
 If Any Leakages Through The Dummies Are Found. Removal Of The
Cylinder Head From The Test Stand To Be Done To Attend The Dummy Or
Nozzle Sleeves Pneumatic Test.
Pneumatic testing
Pneumatic testing is conducted to check leakage or crack developed in the cylinder
head. The following procedure is being followed for pneumatic testing
 The Cylinder Head To Be Connected To Pneumatic Arrangement To Supply
Compressed air into the system for supplying air into the system
 The inlet and outlet of the cylinder head to be properly flanged with gasket
and then it is immersed into the water tank.
 The water in the tank to be heated up to a temperature of 70 ° C to 80 ° C. Let
the cylinder to have a preheating time.
 Air pressure to be incorporated into the system and the air pressure to be 5 kg
/ cm2 .
 If there is any crack in the cylinder head then air will come out of the system
in form of air bubble and in water it is very easy to trace the point of cracking
.
 f any crack found in the cylinder head , then it is taken out of the water tank ;
the pressurized air to be released from the system and rectification to be done
as per the need .
Secondary Suspension :
 The Secondary Suspension Enables Lateral and Vertical Displacements And
Bogie Rotation With Respect To Body When Running Through Curves.
 It Is Implemented By Two Spring Packs Which Sustain The Bolster Beam
Over The Bogie Frame
 Each Spring Pack Is Made Up By An Internal And An External Spring ,
Mounted And Positioned Through The Cantering Discs .

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 An Anti - Roll Bar , Fitted On The Bogie Frame , Realizes A Constant ,
Reduced Inclination Coefficient During Running .
 The Bogic Frame Is Linked To The Bolster Beans Through Two Vertical
Dampers , A Lateral Damper , Four Safety Cables And The Traction Rods .
 The Bogie Frame Is Also Linked To The Coach Body Through Two Yaw
Dampers.
Figure 19 Secondary suspension
Primary Suspension :
Primary Suspension Is Implemented By Two Units Of Two Steel Coil Springs Internal
And External Laid Out On The Control Arm Upper Part By A Cantering Disk And
Adjustment Shims.
The Suspension Is Also Completed By The Following Components.
 Control Arm
 Fitted With Twin Layer Elastic Joints ,
 Connecting The Axle Bearing To The Bogie Frame And Transmitting.

54
 Not Stiffly ,
 Lateral ,
 Longitudinal And Part Of The Vertical Forces
 Vertical Damper.
Rubber Elements Separate The Primary Suspension From The Bogie To Realize
Noise Reduction. Stops And Protections Are Mounted On The Bogie Frame For The
Lifting.
Figure 20 Primary suspension
Foundry Shop Loco Shop.
In Foundry Shop Different Types Of Parts Are Produced Using Casting Process. After
Casting The Work Pieces Are Machined To Convert Them Into Various Parts
According To Part Structure .Various Types Of Furnaces Are Available In At Loco
Shop Of Railway Industry To Cast Different Number Of Parts According To Demand.

55
TYPES OF FURNACES
There Are Different Types of Furnaces Available In Foundry Shop. The Furnaces
Are As Follow
 Cupola Furnace
 Tilt Furnace
 Rotary Furnace
Cupola Furnace
A Cupola Or Cupola Furnace Is A Melting Device Used In Foundries That Can Be
Used To Melt Cast Iron And Some Bronzes. The Cupola Can Be Made Almost Any
Practical Size. The Shell of the Cupola, Being Usually Made Of Steel and Has
Refractory Brick. The Bottom Is Lined In A Similar Manner But Often A Clay And
Sand 3000f Mixture.
Figure 21 Cupola furnace
Tilting Furnace
A Tilt Furnace Is Also A Melting Device Used In Foundries That Can Be Used To
Melt Aluminum And Some Bronzes . It Is Called Tilts Furnace Because Molten
Metal Can Be Get By Tilting The Furnace . The Cupola Can Be Made Almost Any
Practical Size . 550-600 Faluminum.Brass Melting Temp = 1050-1150f.

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Figure 22 Tilting furnace
Rotary Furnace
Rotary Melting Furnace Is Very Flexible & Universal Equipment Used Fore cycling
Many Non - Ferrous Metals .Rotary Furnace Is A Batch Type Process Furnace. It Is
Designed According To Capacity .In Rotary Furnace The Required Quantity Of Raw
Material Is Filled Along With A Proportionate Charge Of Additives .It Is Used To
Melt Raw Iron .
Figure 23 Rotary furnace

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Non Ferrous Foundery Mixtures Brass Foundry
Project: Make To Leaded Bronze
Making pattern.
 Make The Mold Cavity.
 Take Following Material.
 Copper 81%
 Tin 6%
 Zinc 1%
 Lead 12%
 PH.CU 1 %
 Ni 1%
 Putt All Material In Furnace And Give The Temperature 1100°C.

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 When Material In Liquid Form Then Put The Liquid Material In Mould
Cavity.
Project:Phosphorous bronze
 Selecting The Meterial FOR PHOSPHOROUS
 Make The Mold Cavity For Bronze
 During Process Be Careful
 Copper 88%
 Tin 8%
 Lead 1%
 Ph.Cv 3%
 Putt All Material In Furnace
 And After That Burn The Material In Furnace
 Wait The Making These Material In Liquid Form
 Give The Tempeture 1100°C.
 When Material In Liquid Form Then Put The Liquid Material In Mould
Cavity
HAND ON SKILL ACQURIRED
 Make To Leaded Bronze
 Make To C&W Bearing
 Make To Metal Brazing
 Learn The Working Of Furnace Shop.
PROBLEMS ENCOUNTERED
 Furnace Not Burn To Proper Material
 Not Proper Work To Furnace
 Eyes Irritation
 Nose And Throat Irritation

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PROBLEMS SOLVING PROCES
 Introduce To Electric Furnace
 Proper Flow To Safety Rules
 Survey Of The Workshop Environment
SAFETY PRECAUTIONS
 Complete A Thorough Hazard Assessment.
 Have Workers Waer Proper Safety Equipment And Clothing
 Comply With Environmental Regularion
 Be Mindful Of Heatstress.
 Keep Moisture Out.
 Inspect Machinert Before Use.
 Provide Ongoing Training.
 Prevent And Minimize Harful Vibration.
 Wear Shoes
 Keep Open Your Eyes Duringwork
 Waer Gloves
 Avoid To Tucth Heating Tools
CARRIAGE AND WAGON SHOPS
The Mughalpura Railway Workshops, On The Lahore–Wagah Branch Line At
Mughalpura Junction Railway Station (MGPR) In Lahore, Is One Of Several Rolling-
Stock Repair Sites. The Workshop Complex Emerged At Its Present Site In 1904 To
Manufacture, Repair, And Overhaul Passenger Coaches And Freight Wagons For
The North Western State Railway. In 1947, It Was The Only State-Of-The-Art
Workshop For-Pakistan Railways.

60
Figure 24 Carriage and wagon shop
These Are The Following Shops In Which We Have Worked In Carriage And
Wagon Shops.
 POWER PLANT Shop
 Heat Treatment Shop
 Roller Baring Shop
 Motor Shop
Power Plant Shop
In This Shop The Generators And Other Mechanical Parts Of Diesel Engine Used In
Power Van Are Overhauled And Repaired. A Power Van Is Basically A Part Of A
Train Which Consists Of Generators And A Controlling System That Provides
Electrical Power To The Whole Train To Utilize In Form Of Light, Fan Or Air
Conditions. There Are Two Types Of Generators Used In Power Van. IN This Base
Work Overhauling the Generator. One Is 300 Which Is Used In A Combination Of
Two Generators And 500 Which Is Used Alone. There Is Always A Generator Placed
As A Backup Generator In The Power Van For Emergency Conditions Or In Case
Of Overload. The Supply Of Fuel For These Generators Is Taken Through The Diesel
Tank Which Is Placed In The Power Van Separately For Each Generator And Called

61
An Auxiliary Tank. Power Van Has Usually Two People For Operation At A Time
During Working. A Control Panel Is Used To Control Both Generators While
Operating.
In This Shop Work These Are:
 Generators Engine Overhauling
 Repairing And Maintence Power Van
 Nominated Repair Mechanical
 Nominated Repair Electrical
Diesel Generator
A Diesel Generator Is The Combination Of A Diesel Engine With An Electric
Generator (Often An Alternator) To Generate Electrical Energy. This Is A Specific
Case Of Engine-Generator. A Diesel Compression-Ignition Engine Often Is Designed
To Run On Fuel Oil, But Some Types Are Adapted For Other Liquid Fuels Or Natural
Gases. Perkins Engine With Alternator 74 It Is Supplied By Diesel Through An
Auxiliary Tank Which Is Connected To The Main Tank And A Motor Is Used To
Pump Diesel Through The Main Tank To The Auxiliary Tank. A 500 Kva Diesel
Generator Usually Takes 30 Liter/Hour Diesel In Normal Loads And 45 Liter/Hour In
Peak Loads. In This Power Van Are Used To Diesel Generator.The Main Tank Can
Be From Different Ranges But Mostly Used A 3000-Liter Capacity Tank.
Figure 25 Diesel Generator

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PROJECT: CYLINDER HEADS INSPECTION
 All cylinder heads are de-carbonized.
 Inspect cylinder heads. . Inspect valve spindles.
 Carry out the Inspection of Inlet, Exhaust valves & Inlet valve guides.
 Record the measurements. Replace the Corroded & worn out valve guides
with the new one.
 Inspect valve seats and reject the excessively dented. Pitted, and uneven
working surfaces. Accepted valve seats are to be re grounded with the
machine .
 Dismantle all the valve rotators for inspection. Observe for deep markings on
the inclined surfaces of ball pockets.
 Inspect all the Injector Sleeves and record the observations.
 Adjust the opening pressure to 170 bars.
 Inspect Indicator Valves
 And After That Open The Cylinder Head.
 Inspect Cylinder Head Cooling Water Spaces.
 Carry Out The Lapping Of Cylinder Head Seating Face.
 Carry Out The Pressure Testing Of All The Cylinder Heads.
 Carry Out All Cylinder Head Valve Seat Grinding Work Old New Seats.
 All Water Guide Jackets Are To Be Removed, Clean, Inspect And Fit Back
With New O Rings. Tighten All The Nuts For Cylinder Heads With
Prescribed Torque As Per The Orem Instructional Manual.
Cylinder Liner Inspection
 Pull Out All Cylinder Liners For Inspection.
 Inspection / Bore Measurement And Honing To Be Carried Out At Workshop
As Per Orem Procedures For Inspection And Honing Of Cylinder Liner.
 Enter The Records Of Size Into The Forms.
 Carry Out The Lapping Of The Cylinder Liner's Upper Face.
 Replace All The Flame Rings With An Excessive Worn - Out Working
Surface.

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Crankshaft and Main Bearings inspect all the crankpins
 Polish all main & CR pins with glossy paper.
 Inspect & replace thrust bearings if wear is more than the prescribed limit.
 Re - tighten counterweights at the specified torque
 . Dismantle all main directions & Polish all the Crank - pin
 Carry out the Tightening of main and guide bearing caps at the prescribed
torque
 Check and replace all main bearing if found with abnormal wear down
Camshaft and Camshaft Bearings
 Inspect All Gear Wheels Bolt And Connection As Per OEM Instructions.
 Replace All Camshaft Bush If Found Worn Out.
 Check The Condition Of A Camshaft. . Check The Lubrication Of The
Camshaft. Observe The Flow Of Lube Oil From All The Bearings And Spray
Pipe Nozzles. The Oil Jet Should Be Hitting At The Gearwheel Right At The
Meshing Point.
 Check The Tightness Of All The Fasteners, Including Locking Devices.
Hand On Skill Acquired
 Diesel Engine Overhauling
 Brake Inspection
 Oil Change
 Cylinder Liner Inspection
 Check Engine Missing
 Engine Diagnosing
Problemes Encountered
 Engine Over Heating
 Engine Noise
 Engine Missing
 When Engine Enter The Workshop Leave To Engine Black Smog

64
Safety precautions
 Avoid To Heating Parts.
 Wearing Proper Work Gloves.
 Proper Electrical Safety.
 Never Use To Gasolian As A Solvent Or To Clean Rngine Parts.
 Maintain Social Distancing.
 Follow To Workshop Safty Rule.
 Avoid To Moving Parts.
 Keep Oprn Your Eyes During Work.
 Waer The Safety Gloves.
 Keep All Shield In Place.
Heat Tretment:
Project: Screw Coupliing Heat Tretment Process
 Take The Screw Coupling.
 Putting the Screw Coupling Into Furnace.
 Give The Temperature 825 To 860°C.
 After heating On the Tempeture Take out The Screw Coupling Form
Furnace.
 Quench The Screw Coupling I Oil 550 To 610 35 To 45 Minutes.
 After Soaking Period Putt The Screw Coupling Again The Furnace.
 Give The Tempeture 550 To 610°C.
 After Heating On This Tempeture Take out The Screw Coupling Form
Furnace.
 Allow The Screw Coupling To Cool In Air For 30 To 45 Minutes.

65
Figure 26 Screw coupling
Hand On Skill Acqurired
 Make To Screw Couling.
 Improving The Material Quality’
 Improving The Toughness.
 Over Heating And Burning
 Oxidation
 Decarburizaton
 Breakage
 Cracking
Roller Baring Shop:
There Are Three Basically Bering Use in Locomotive.
 Cylindrical Roller Bearing
 Spherical Roller Bearing.
 Taper Roller Bearing.
Cylindrical Roller Bearing.
Cylindrical Roller Bearings These Bearings Feature Rollers That Are Longer Than
Their Diameter, And Can Tolerate Higher Loads Than Ball Bearings. Our

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Cylindrical Roller Bearings Can Carry Heavy Radial Loads And Are Able To Be
Used In High - Speed Applications.
Figure 27 Cylindrical Bearing
Spherical Roller Bearing
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.

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Figure 28 Spherical Roller Bearing
Taper Roller Bearing.
Taper Roller bearings these 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.
Figure 29 taper Roller Bearing
Project: Removing the Bering by Wheel.
 Separate the wheel seats in train bodies
 Remove the traction motor.

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 Take a puller.
 For removing and installing railway bearing sets and labyrinth ring special
induction heats can be used.
 Give to heating bearing with the help of puller.
 Puller working on hydraulic pressure.
 Puller operate to electrical.
 When the loss of bearing take on remove by the wheel.
Figure 30 Puller

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Figure 31 Bearing removing
Motor Shop C&W Shop
Project: diesel engine overhauling
Cylinder head overhauling
 Replace the valves.
 Replace the valve guides.
 Take on replace the valve sleeves.
 In addition to the above it is often necessary to repair machine the cylinder
head shell, which we can also carry out at RS motor.
 Once the cylinder head is restored we proceed with a final hydraulic test.
Connecting Rod Reconditioning.
 Open The Engine Block.
 Verification Of The Parallelism Of The Connecting Rod Body.
 If It Is With In The Dimension Required By The Manufacturer New
Connecting Rod Foot Bushes And New Connecting Rod Foot Bushes
And New Bolts Or Studs Are Installed.

70
Check OF STATER MOTOR
 Check The Electric Connection.
 Check The Motor Welding
Cooling System Checking
 Check The Condition Of Radiator.
 Check The Thermostat Valve.
 Check The Condition Of Water Pump.
 Check coolant levels
 Check to fan belt.
Ultrasonic intercooler cleaning
 Disassembly Go The Intercooler
 Ultrasonic Cleaning
 Mechanical Of Covers And Body
 Replacement Of Sealing Elements Complete Assembly
 And Final Hydraulic Test.
Check the crankshaft measurements
 Separate To All Parts Of Crankshaft
 Separate To Connecting Rod
 Check The Measurements Of Crankshaft
 Dimensional Verification Of All Crankshaft Measurements Using
Equipment Specially Designed For This Purpose.
Lube oil cooler overhaul
 Complete Disassembly
 Replacement Of Sealing Elements
 Again Assemble
 Take On Hydraulic Test
Check lubrication system
 Check Oil Filter.

71
 Check Oil Pump.
 Check Oil Seals
 Check Gasket.
 Oil Leakages Check
Recovering the block
 When It Is The Necessary To Carry out Some Work Such As Marching The
Upper And Lower Parts Of The Engine Block
Renovation of the main engine parts
 Pistons
 Connecting Rod
 Bearing
 Cylinder Liners
 Cylinder Head Gasket
 Thrust Bearing
 Camshaft Bushes
Hand on skill acquired
 Learn To Piston Replace
 Learn To Crankshaft Replace
 Learn To Camshaft Replace
 Learn To Cylinder Block Replace
Problems encountered
 Engine Overheat
 Oil Leaked
 Black Exhaust Smoke
 Engine Missing
 Reduce Engine Performance Noises

72
 Waiting Engine Cooling
 Stopping The Oil Leakage
 Check Air Flue Ratio
 Engine Run To Normal Tempeture
Safety at Work
 Use To Safety Gloves
 Keep Open Your Eyes
 Respirators
 Hearing Protection
 Safety Footwear
 Coveralls And Apron
 Fire Safety
Figure 32 Diesel Engine

73
Central laboratory
Central Laboratory Is A Material Testing Lab Is A Facility Dedicated To Conducting
Experiments And Analyses To Evaluate The Properties And Behaviors Of Various
Materials. It Serves As A Crucial Component In Industries Such As Manufacturing
.Construction, Engineering, And Research And Development. The Lab Is Equipped
With Specialized Equipment And Instruments That Allow For Precise Measurements
And Simulations To Be Performed On Different Types Of Materials , Including Metals
, Polymers , Ceramics , Composites , And More .Material Testing Labs Typically Offer
A Wide Range Of Tests To Assess Mechanical , Physical , Thermal , Electrical , And
Chemical Properties Of Materials . These Tests May Include Tensile And Compressive
Strength Tests. Hardness Tests. Impact Tests. Fatigue Tests, Creep Tests Corrosion
Tests , Thermal Conductivity Tests, And Many Others . The Lab Technicians Or
Engineers Follow Established Testing Standards And Protocols To Ensure Accurate
And Reliable Results.
Brinell hardness
A Brinell Hardness Testing Machine Is A Device Used To Measure The Hardness Of
Materials Based On The Brinell Hardness Scale .It Typically Consists Of A Sturdy
Frame , A Hydraulic Or Mechanical Load System , And A Spherical Indenter Made
Of Hardened Steel Or Carbide . The Test Involves Applying A Predetermined Load
To The Material Being Tested.
Rockwell hardness
A Rockwell Hardness Testing Machine Is A Device Utilized To Measure The
Hardness Of Materials Based On The Rockwell Hardness Scale.It Typically Consists
Of A Robust Frame , An Adjustable Vertical Load System , And Diamond Or
Hardened Steel Indenters . The Test Involves Applying A Minor Initial Load.
Universal Testing Machine
A Universal Testing Machine Is A Versatile And Powerful Mechanical Device Used To Perform
A Wide Range Of Tests On Materials. It Consists Of A Sturdy Frame, An Adjustable Load
System, And Various Grips Or Fixtures To Secure The Specimen Being Tested.

74
Chapter 5: Conclusion
The Internship program completed in Railway Workshops is one of the best practical
experiences gained so far .A lot of different tasks are assigned and completed by us
in groups and individually too . The basic knowledge about practical circuits
operating in industry is observed during the training period . Power House equipment
are major part of learning process and we practiced operating mechanism along with
structural model of each equipment and machinery . The overall working experience
in each workshop was kind of intellectual and diversified .I learnt how to manage
workload in any working site and gain experience from those who are working
alongside . I am sure that the practical skills and knowledge got from this Internship
program will definitely help me during my professional life ahead . Finally, I would
like to thank my instructors and all the person of this organization who had helped
me a lot during my internship.
Recommendation:
 Making good management
 Use latest machinery.
 Make clean environment.
 Apply rules and regulation with every persons.

75
Chapter6: Reference
https://rsmotorps.com/en/diesel-engine-overhaul/
https://www.scribd.com/document/527439743/Diesel-Generator-Overhauling-Procedure-
21-22-Best-Practice
https://www.pon-cat.com/en-nl/services/power/all-services/engine-overhaul/engine-
overhaul

Final report(19AU012).pdf Supervised Industrial Training

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