Internship at Pakistan Railways

PAKISTAN RAILWAYS
REPORT ON WORKSHOPS OF RAILWAY
SUBIMMTED To: -
METC
SUBMITTED BY: -
MUHAMMAD USMAN
(2015-ME-12)
PH # 03354770766
MECHANICAL ENGINEER
UNIVERSITY OF ENGINEERING & TECHNOLOGY, LAHORE

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Acknowledgement
First of all I’m very thankful to Allah Almighty who blessed me and made capable to complete
this task. After that, I’m grateful to Pakistan Railways department (especially METC) which
provided me the opportunity to do Internship, over there.
It pleasures me a lot in paying tribute to all the staff members working at Railways department
thus showing their zeal and zest attitude towards their working area. Their support in guiding
me the technical points of the work being done at workshops, is greatly appreciable. This
helped me significantly in the completion of my report.
This training wasn’t possible if the Chairman of Mechanical Engineering Department Dr. Nasir
Hayat would not have allowed in the first place. So, thanks for him as well.

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Table of content
1. Introduction………………………………………………………………………... 5
2. Workshops………………………………………………………………………….. 5
2.1 E & DC shop…………………………………………………………………….... 5
2.2 Diesel Classified Shop…………………………………………………………….. 9
2.3 Machine Shop……………………………………………………………………. 13
2.4 Spring Shop……………………………………………………………………… 14
2.5 Power Plant Shop……………………………………………………………...... 17
3. Conclusion………………………………………………………………………… 17
4. Suggestions and Improvements………………………………………………….. 17
5. Future horizons for the students………………………………………………… 18
6. References………………………………………………………………………… 19

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List of Figures
Figure no. Description Page no.
1 Machining of Engine Block 6
2 Machining of Connecting Rod 6
3 Rotor Assembly 7
4 Cylinder Head valve 7
5 Connecting rod 7
6 Hub and Gear 7
7 Suspension bearing 8
8 H.P Piston 8
9 Bearing Housing 8
10 Crankshaft 9
11 Locomotive 9
12 Parts of shaper machine 14
13 Spring formation 14
14 Types of spring 15
15 Bars 15
16 Heating of Heads 16
17 Pressing of heads 16
18 Coiling of spring 16
19 Spacing of spring 16
20 Hardening of spring 16
21 Tempering of spring 17
22 Painting of spring 17

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PAKISTAN RAILWAYS: -
Pakistan Railways is the national, state owned railway company of Pakistan whose
headquarter is at Lahore and was founded in 1861. It owns 7400 miles from Torkham to Karachi thus
transporting freight and passenger services. Ministry of Railway has launched many projects for the
development, renovation and up gradation of Locomotives, the infrastructure and passenger services.
China-Pakistan Economic Corridor is the leading example of these projects which lasts for Rs886.68
billion with a duration of 2025.
Workshops: -
There many Railway Workshops sectors in Pakistan. The Moghalpura Railway Workshop
at Lahore-Wagah Branch Line Moghalpura Junction railway station in Lahore is one of the leading
sites. There are many workshops at this site.
Mechanical Workshops: -
The main locomotive workshops of the Pakistan Railway may be either situated at the
same station as the main carriage and wagon workshops or at different stations. In addition to the
repairs and reconditioning of Locomotives & rolling-stock and of plant and machinery and the
manufacture of the spare parts for the repair thereof, these workshops often carry out work of the
nature shown below:
(1) Construction of goods wagons.
(2) Overhauling of:
Locomotives.
Coaching Vehicles.
Goods Vehicles.
(3) Manufacture of articles/spares required for the repairs of locomotives & rolling stock and for
the Stores Department for general use.
(4) Manufacture of articles of various kinds for,
Other Government Departments.
Foreign Railways.
Others.
We did internship for period of 15 days in the following workshops: -
1. E & DC (Electric and Diesel Component) Shop C.C. 7019
2. Diesel Classified Repair Shop C.C. 7026
3. Machine Shop
4. Carriage and Wagon Shop
5. Power Plant Shop
E & DC (Electric and Diesel Component) Shop C.C. 7019: -
We visited E & DC shop for three days (January 16 to 18). After the Diesel Components have
been casted, they were sent in this shop for machining process. There were many sections in this shop
as given below: -
 Lathe Section
 Milling Section
 Fitting Section
 Grinding Section

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 Welding Section
Lathe Section: -
In this section there were many different Lathe Machines performing several operations. After the
Diesel Components have been casted, they were sent in this shop for machining process. Facing,
Turning, Boring, Tapering, Boring and Parting were the major operations performed over there. This
section included the machining of Bearings, Wheels, Pistons, and Connecting Rods etc.
Milling Section: -
After the casting, some of the diesel components were sent in the milling section. It included many
milling machines thus performing several operations. Diesel Components i.e. Engine Block, Washers,
Rotor, Motor Cap, Jigger, Crankshaft and Cylinder were milled in this section.
Fitting section: -
This section included the machining of fitting components for their use in Locomotive. It included
Compressor Blades etc.
Grinding Section: -
After the components have been machined they were sent to the grinding section for their precision
purposes. Many Grinding machines were used for their different operational purposes. Magnetic
Chucks were used to hold some components such as Washers, Piston and Rotor Shaft etc. Water as
Coolant was continuously used for the Grinding purposes.
Welding Section: -
This section included the welding of different components such as Compressor Blades etc.
Machined Parts: -
Figure 1 Machining of Engine block Figure 2 Machining of Connecting rod

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Parts that were machined in all these sections are as given below: -
Figure 4 Cylinder Head Valve
Figure 5 Connecting Rod
Figure 6 Hub & Gear
Figure 3 Rotor Assembly

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Figure 7 Suspension Bearing
Figure 8 H. P Piston
Figure 9 Bearing Housing

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Figure 10 Crankshaft
Diesel Classified Repair Shop C.C. 7026: -
This workshop was about the repairing, mending and over allying of an entire Diesel Engine along
with its corresponding systems. As our project with China also contained the over allying procedure
of their Engines along with bringing new ones. China Engine needs a complete over allying procedure
at least after 3 years in order to meet the proper running condition of the engine. Chinese were called
upon the site for this process.
Parts of Locomotive: -
There are several parts of a Locomotive as given below and demonstrated in figure: -
 Diesel Engine
 Lubricating System
 Main Generator
 Battery
 Cooling System
 Air Compressor
 Compressed air
reservoir
 Sandbox
 Ventilator
 Radiator
 Air Filter
 Fuel tank
 Dynamic Brake
 Driver’s Cab
Reading Constraints in the Cabin of Locomotive: -
Driver of Locomotive notes the following readings to ensure the proper working of the Train.
Figure 11 Locomotive

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1. Pressure Gage (brake)
2. Pressure Gage (cylinder)
3. Status Indicator
4. Unloaded, Total overflow, Grounding, Aux Convertor Cabinet Fault
5. Water level is too low
6. Diesel engine alarming
7. Computer alarming
8. Self-load
9. Brake pipe pressure is too low
10. Compressor is running
11. R brake alarming
12. Sliding of wheel
13. Engine speed
14. Accu. generator voltage
15. Main generator current
16. Main generator voltage
Here, are the factors which affects the running Engine to trip/ stops running if they are not notified.
So, they must be regularly checked to ensure Engine’s proper working. Moreover, the driver sitting
in cabin also note these parameters in his journey. These factors are given below: -
 Temperature of the Coolant
 Pressure of lubricating oil
 Fuel Capacity
Locomotive Inspection and its Maintenance Schedule: -
Maintenance of a Locomotive is a complete job. Here, is a table in which there is a complete
schedule of its inspection, time taken to complete and the parameter which are inspected during this
process.
Table 1 Inspection Schedule and time
Inspection Schedule Time of completion
A - Schedule (After every trip) 1 hrs
B - Schedule (Monthly) 2 hrs
C - Schedule (Every 3 Monthly) 8 hrs
D - Schedule (Every 6 Months) 8 hrs
E - Schedule (Every 9 Months) 8 hrs
F - Schedule (Annual) 16 hrs
Inspection Parameters: -
1. A-Schedule
Fuel oil & lube check.
Expressor discharge valve.
Flexible coupling’s bubbles.

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Turbo run down test.
Record condition of wheels by star gauge.
Record oil level in the axle caps for suspension bearing.
2. A-Schedule
All the valves of the Expressor are checked.
Primary and secondary fuel oil filters are checked.
Turbo super charger is checked.
Under frame are checked.
Lube oil of under frame checked.
3. B, C-Schedule
All the works done in T-2 schedule.
All cylinder head valve loch check.
Sump examination.
Main bearing temperature checked.
Expressor valve checked.
Wick pad changed.
Lube oil filter changed.
Strainer cleaned.
Expressor oil changed.
4. D-Schedule
Run engine; check operation of air system safety valves and Expressor crankcase lube oil
pressure.
Stop engine; carry out dry run operational test, check FIP timing and uniformity of rack
setting and correct if necessary.
Engine cylinder head:-Tighten all air and exhaust elbow bolts, check valve clearance,
exhaust manifold elbow etc.
Engine crankcase cover:-Remove crankcase cover and check for any foreign material.
Renew gaskets.
Clean Strainer and filters, replace paper elements.
Compressed air and vacuum system:-Check, clean and recondition rings, piston, Intake
strainers, and inlet and exhaust valve, lube oil relief valve, unloading valve. Drain, clean
and refill crankcase.
Radiator fan- tightens bolts and top up oil if necessary.
Roller bearing axle boxes. Check for loose bolts, loss of grease, and sign of overheating.
Remove covers, clean and examine roller races and cages for defects. Carry out ultrasonic
test of axles.
Clean cyclonic filters, bag filters and check the condition of rubber bellows of air intake
system.
Renew airflow indicator valve.
Carry out blow bye test and gauge wheel wears.
5. F-Schedule
Repeating of all items of trip, quarterly and monthly schedule.
Testing of all valves of vacuum/compressed air system. Repair if necessary.
Replacement of coalesce element of air dryer.

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Reconditioning, calibration and checking of timing of FIP is done. Injector is
overhauled.
Cleaning of Bull gear and overhauling of gear-case is done.
RDP testing of radiator fan, greasing of bearing, checking of shaft and keyway.
Examination of coupling and backlash checking of gear unit is done.
Checking of push rod and rocker arm assembly. Replacement is done if bent or broken.
Checking of clearance of inlet and exhaust valve.
Examination of piston for cracks, renew bearing shell of connecting rod fitment.
Checking of connecting rod elongation.
Checking of crankshaft thrust and deflection. Shims are added if deflection is more
than the tolerance limit.
Main bearing is discarded if it has embedded dust, gives evidence of fatigue failure or
is weared.
Checking of cracks in water header and elbow. Install new gaskets in the air intake
manifold. Overhauling of exhaust manifold is done.
Checking of cracks in crankcase, lube oil header, jumper and tube leakage in lube oil
cooler. Replace or dummy of tubes is done.
Lube oil system- Overhauling of pressure regulating valves, by pass valve, lube oil
filters and strainers is done.
Fuel oil system- Overhauling of pressure regulating valve, pressure relief valve,
primary and secondary filters.
Checking of rack setting, governor to rack linkage, fuel oil high-pressure line is done.
Cooling water system- draining of the cooling water from system and cleaning with
new water carrying 4 kg tri-phosphate is done. All water system gaskets are replaced.
Water drain cock is sealed. Copper vent pipes are changed and water hoses are
renewed.
Complete overhauling of water pump is done. Checking of impeller shaft for wear and
lubrication of ball bearing. Water and oil seal renewal.
Complete overhauling of expressor/compressor, pistons rings and oil seal renewed.
Expressor orifice test is carried out.
Complete overhauling of Turbo supercharger is done. Dynamic balancing and Zyglo
test of the turbine/impeller is done. Also, hydraulic test of complete.
Turbo supercharger is done.
Overhauling of after-cooler is done. Tell-tale hole is checked for water leak.
Inspection of the crankcase cover gasket and diaphragm is done. It is renewed if
necessary.
Rear T/Motor blower bearing are checked and changed. Greasing of bearing is done.
Cyclonic filter rubber bellows and rubber hoses are changed. Air intake filter and
vacuum oil bath filter are cleaned and oiled.
Radiators are reconditioned, fins are straightened hydraulic test to detect leakage and
cleaning by approved chemical.
Bogie- Checking of frame links, spring, equalizing beam locating roller pins for free
movement, buffer height, equalizer beam for cracks, rail guard distance is done.
Refilling of center plate and loading pads is done. Journal bearings are reconditioned.
Axle box- cleaning of axle box housing is done.
Wheels- inspection for fracture or flat spot. Wheel are turned and gauged.
Checking of wear on horn cheek liners and T/M snubbed wear plates.
Checking of brake parts for wear, lubrication of slack adjusters is done.

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Inspection for fatigue, crack and distortion of center buffers couplers, side buffers are
done.
Traction motor suspension bearing- cleaning of wick assembly, checking of wear in
motor nose suspension. Correct fitment of felt wick lubricators is ensured. Axle boxes
are refilled with fresh oil. Testing of all pressure vessels is carried out.
Machine Shop c.c. 7005: -
Machine shop was a very large workshop having different machining apparatuses. This shop
was bit similar to E & DC shop but the difference was in the size of apparatuses. This shop had very
large machining systems and operations. This shop included machines like Lathes, Milling, Drilling,
Boring, Shaper, Planer and Slotter etc. Many machines had three to four tool posts i.e. many jobs
could be done in less time. Moreover, large components were machined in this shop which could only
be lifted by cranes only. Components included are: -
 Engine Blocks
 Coupling rods
 Bearings
 Axles
 Rail Wheels
 Rail joints
 Fish plates
 Anchors
 Bogie components
Some of the machines were studied and analysed in detail, such as: - Shaper and Planar machine,
Drilling and Boring machine etc. Their structure, parts and working were mainly focused. The
criteria to study every machine was to start from its base. Some common parts included in all
machines were as follows: -
Base: - Provides support for the whole structure and absorbs the vibrations produced during the
operation.
Table: - The main function of the table is to hold the job.
Column: - It supports the upper part of the machine i.e. the head and covers the internal assembly of
the machine i.e. gears system, belts and motors etc.
Tool Head: - Supports the tool for the cutting operational purposes.
Feed: - It is defined as the material removed in one cut. It is provided by the operator of the machine.
Speed: - It is provided by the motor to the tool or workpiece according to the specifications.

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Figure 12 Parts of shaper machine
Spring and Carriage Shop: -
Spring shop is one of the most fundamental workshops at railways, in which springs and helical
are prepared and manufactured. The purpose of these springs is, in the absorption of shock and
controlled application in the storing and releasing energy.
Figure 13 Spring Formation
The types of springs include: -
Buffer spring
Coil Helical spring
Leaf spring

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Figure 14 Types of springs
The steps involved in making the springs as follows along with their images: -
1. Cutting
2. Heating of coil head
3. Heating in bar heating furnace
4. Coiling of spring
5. Spacing of spring
6. Hardening
7. Tempering
8. Scarg test
9. Load test
10. Finishing and grinding
11. Painting
Figure 15 Bars

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Figure 16 Heating of Heads
Figure 18(a) Coiling of spring
Figure 19 Spacing of spring
Figure 17 Pressing of Heads
Figure 18 (b) Coiling of spring
Figure 20 Hardening of spring

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Figure 22 Painting of spring
Power Plant: -
Power Plant workshop at Pakistan Railways was also one of the good sources of learning
practical knowledge. This workshop basically was about the production of energy, its utilization and
its distribution etc. The generators involved in the production purposes and the cycle upon which they
are operated, were examined practically.
The Forman at the power plant does his duties in running the power house, distribution of energy and
maintenance of power plant of efficient working.
Conclusion: -
Internship at the railways was a great opportunity of learning practical knowledge about
my field of study. Both Pakistanis and Chinese workers were working together thus showing their
zeal and zest efforts for lifting up their speed of work.
By training under the five workshops I got familiarized myself much about the practical works that
is being done in the industries. The manufacturing of components of train, machining of the casted
products, assembly and alignments of equipment’s and overlaying or maintenance of locomotives all
are the extreme source of practical knowledge.
Suggestion and Improvements in the department: -
 Railway department should upgrade its system of transferring the letters, applications and
other various documents to its other departments i.e. by use of internet technology.
 It must use the banking transection system for the comfort of people and more safety of its
cash.
 As most of the machinery systems are installed since 19th
century, so railway department
ought to revolutionise its system (with the latest ones) in order to compete with the modern
railway industries of the world.
 Latest methods and techniques should be adopted for the up gradation of the previous ones,
for example the check and balance of all the worker’s work should be more regulated along
with the use of biometric attendance system, for the advancements in work.
Figure 21 Tempering of spring

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 Moreover, there was a lot heat loss during the formation of helical. Much gas was wasted so
in order to minimize the loss, sections should be introduced in the furnace for maximum heat
gain by the bars. Labours should be more efficient in working and saving time as much as
possible during the burning of gas.
Future Horizon for the Students: -
Pakistan Railways is one of the best departments for the trainings and internships programme for the
graduating students. The students of Mechanical, Electrical, Metallurgy, Mechatronics and
Manufacturing etc. discipline can learn a lot of practical knowledge by doing internships over there.
They would be able to relate the theoretical knowledge (learnt in universities) with the practical ones,
by observing the work, in a better way. They would have a clear point of view for how the things
work, in practical life i.e. dealing with the machineries and people.

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References: -
1. https://en.wikipedia.org/wiki/Pakistan_Railways
2. https://www.slideshare.net/ahmedalvi01/railway-internship-presentation
3. https://www.slideshare.net/ashokKumar2953/ajmer-railway-locomotive-training-report
4. https://www.slideshare.net/AmanKashyap4/diesel-shed-izzatnagar-report

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