Saqib 19AU014 Industry training report.pdf

INDUSTRIAL TRAINING
REPORT
PAKISTAN RAILWAYS
Name: Saqib waheed
Roll No: 19AU041
Industrial Training Course: Supervised Industrial Training-1
Training Period: 27-03-2023 to 22-07-2023 (16 WEEKS)
Training Organization: Pakistan Railways Mugalpura

ABSTRACT
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 (Mugalpura
Workshops). 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 maintain ability 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. I am pleased with what I have done
here, and what I have liked the most is the possibility to go through with what you are
working and to have the necessary time to carry things out.

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.

Contents
ABSTRACT............................................................................................................................................................2
ACKNOWLEDGEMENT ......................................................................................................................................3
Chapter 1: Backgrounds of the Pakistan Railway...................................................................................................8
Pakistan Railway History....................................................................................................................................8
Structure..............................................................................................................................................................9
Railway Board ....................................................................................................................................................9
Functional units.................................................................................................................................................10
Divisions ...........................................................................................................................................................10
Manufacturing...................................................................................................................................................10
Future Restructuring .........................................................................................................................................12
New lines ..........................................................................................................................................................12
ORGANIZATIONAL STRUCTURE:..............................................................................................................13
Chapter 2...............................................................................................................................................................14
My training schedule.........................................................................................................................................14
Chapter 3...............................................................................................................................................................15
Work experience...................................................................................................................................................15
Chapter 4...............................................................................................................................................................21
DIESEL CLASSIFIED REPAIR SHOP...............................................................................................................21
LUBRICATING SYSTEM...............................................................................................................................21
Engine Fuel injectors.........................................................................................................................................22
Traction motor...................................................................................................................................................22
Cooling system..................................................................................................................................................22
Prime Mover .....................................................................................................................................................23
Locomotive and Diesel Engine Parts:...............................................................................................................24
Bogie assembly section.....................................................................................................................................24
Locomotives for overhauling ............................................................................................................................25
Wheel Assembly ...............................................................................................................................................26
Wheels Dismounting Machine..........................................................................................................................26
ADVANTAGES OF SUPER CHARGED ENGINE........................................................................................28
Classification of railways locomotives:.............................................................................................................28
3000 H.P V-type 16 cylinders locomotives.......................................................................................................28
2000 H.P V-type 12 cylinders locomotives.......................................................................................................28
Primary suspension: ..........................................................................................................................................30
E & DC SHOP ......................................................................................................................................................31
Oil seals.............................................................................................................................................................33
Friction plate .....................................................................................................................................................33
Shell Bearing.....................................................................................................................................................33
Lathe machines .................................................................................................................................................34
Milling Section..................................................................................................................................................34

Grinding Machine .............................................................................................................................................35
Fitting Section...................................................................................................................................................35
TOOL SHOP.........................................................................................................................................................36
Milling Section..................................................................................................................................................37
Lathe Section ....................................................................................................................................................37
Grinding Section...............................................................................................................................................38
Fitting Section...................................................................................................................................................38
Die Section........................................................................................................................................................40
Rehabilitation shop ...............................................................................................................................................41
Supervisory Work in the Rehabilitation Shop:.................................................................................................41
Disassemble Section: ........................................................................................................................................41
Bogie of Locomotive ........................................................................................................................................42
Main Component of bogie are fellow...............................................................................................................43
Central Pivot .....................................................................................................................................................43
Traction Motor:.................................................................................................................................................43
Hand on Skills In Rehabilitation Shop..............................................................................................................43
Pre-Inspection:..................................................................................................................................................43
Final Inspection.............................................................................................................................................44
Project Carried Out in the Rehabilitation Shop.................................................................................................44
Rehabilitation Maintenance Loco Engines ...................................................................................................44
Preventive Maintenance of the PR Locomotives.........................................................................................44
PR Steam and Diesel Locomotives...............................................................................................................45
Schedule shed maintenance of PR Locomotives...............................................................................................46
Electric Locomotives ........................................................................................................................................48
Rolling Stocks...................................................................................................................................................50
Classification of railways locomotives .............................................................................................................50
EMD 645...........................................................................................................................................................50
ENGINE CONTROL UNIT .............................................................................................................................53
Problems Encountered......................................................................................................................................54
Problems Solving..............................................................................................................................................55
Safety at Work ..................................................................................................................................................56
Work Experience in Rehabilitation shop ..........................................................................................................56
FOUNDRY SHOP ................................................................................................................................................57
Parts prepared in brass foundry.........................................................................................................................57
Parts prepared in iron foundry...........................................................................................................................57
CASTING:........................................................................................................................................................58
Mould Preparation:............................................................................................................................................59
Sand used in molding process...........................................................................................................................59
Green sand mould : ...........................................................................................................................................59
Dry sand mould :...............................................................................................................................................59

Place brake pads mold in Sand..........................................................................................................................59
Pouring of Molten Metal...................................................................................................................................60
Fettling Process.................................................................................................................................................60
POWER SHOP .....................................................................................................................................................61
Diesel Generator ...............................................................................................................................................62
Parts of a Diesel Generator:...............................................................................................................................63
Control Panel: ...................................................................................................................................................67
Circuit Breaker:.................................................................................................................................................67
HEAT TREATMENT SHOP.............................................................................................................................69
Steps in Heat Treating Operation:.....................................................................................................................69
Types of Heat Treatment Processes ..................................................................................................................70
Types of Heat Treatment...................................................................................................................................71
Annealing......................................................................................................................................................71
Normalizing ..................................................................................................................................................71
Hardening......................................................................................................................................................71
Tempering.....................................................................................................................................................71
Nitriding........................................................................................................................................................72
Purpose of Nitriding..........................................................................................................................................73
Cyaniding..........................................................................................................................................................73
Purpose of Cyaniding........................................................................................................................................73
Carburising........................................................................................................Error! Bookmark not defined.
Case hardening or surface hardening ................................................................................................................73
Purpose of Heat Treatment of Steel...................................................................................................................75
The following are the purposes of heat treatment. ........................................................................................75
Furnaces........................................................................................................................................................75
Batch furnaces...............................................................................................................................................75
Box-type furnace...........................................................................................................................................75
Roller Bearings shop.............................................................................................................................................77
Cylindrical roller bearings.................................................................................................................................77
Spherical roller bearings....................................................................................................................................77
Needle roller bearings .......................................................................................................................................78
Taper roller bearings .........................................................................................................................................78
Advantages and disadvantages ofanti-friction bearings: ..................................................................................79
Advantages:...................................................................................................................................................79
Disadvantages:..............................................................................................................................................79
MOTOR SHOP.....................................................................................................................................................80
Working of Diesel and Petrol Engines..............................................................................................................80
Difference .........................................................................................................................................................81
DIESEL ENGINE OVERHAULED.................................................................................................................81
SIGNS YOUR DIESEL ENGINE MAY BE IN NEED OF AN ENGINE OVERHAUL ...............................82

Steel shop :-...........................................................................................................................................................84
Introduction :- ...................................................................................................................................................84
Purpose of Steel Shop :-....................................................................................................................................84
Conventional Laboratories:- .............................................................................................................................85
Spectrometer :-..................................................................................................................................................86
Mechanical Testing :- .......................................................................................................................................87
Tensile test :-.....................................................................................................................................................87
Testing Machine................................................................................................................................................87
Yield point :-.....................................................................................................................................................89
Chapter 4: Conclusion...........................................................................................................................................90
Recommendations:................................................................................................................................................92
Chapter 5: References:..........................................................................................................................................93

Chapter 1: Backgrounds of the Pakistan
Railway
Pakistan Railway History
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 Torkham 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.
Between 1880 and 1947, the North Western State Railway expanded
throughout Punjab and Sindh. Locomotives were standardized following a report from

The Locomotive Committee on Standard Locomotives for Indian Railways, published
in1910.
North Western State Railway (The Eagle)
Following independence in 1947, most of the North-Western State Railway
infrastructure was in Pakistani territory and was renamed the Pakistan Western Railway.
In East Bengal, the portion of the Assam Bengal Railway in Pakistani territory was
renamed the Pakistan Eastern Railway. The country adopted 8,122 km (5,047 mi) of the
North-Western State Railway; 6,880 km (4,280 mi) was 1,676 mm (5 ft. 6 in), 506
kilometers (314 mi) was 1,000 mm (3 ft. 3+3
⁄8 in) meter gauge, and 736 kilometers
(457 mi) was 762 mm (2 ft. 6 in) narrow gauge.
Structure
Pakistan Railways is a state-owned enterprise under the Ministry of Railways (MoR)
ofthe government of Pakistan, tasked with and primarily responsible for planning,
administrating and establishing passenger rail service and regulating railway companies
and industries. Pakistan Railways policy and development are administered by the
ministry.
Railway Board
The Railway Board, in existence from 1959 to 2000, was modified with an executive
committee between 2000 and 2014. The Railway Board was reconstituted on 20
February 2015. The Board members are

 Federal Secretary Railways (Chairman of Board)
 Federal Secretary of Communications
 Finance Secretary of Pakistan
 Planning and Development Secretary of Pakistan
 General Manager Railways (Operations)
 General Manager Railways (Manufacturing and Services)
 Member Finance, Ministry of Railways
Functional units
Pakistan Railways comprises three functional units:
 Operations
 Manufacturing
 Welfare & special initiative unit
Divisions
Pakistan Railway comprises seven territorial operating divisions:
 Karachi
 Lahore
 Multan
 Peshawar
 Quetta
 Rawalpindi
 Sukkur
Manufacturing

The Pakistan Locomotive Factory was built in Risalpur in 1993 at a cost of ₨228.4
million (US$1.4 million). The factory's capacity is 150 coaches per year on a single-shift
basis.
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.
The railway owns five concrete sleeper factories in Sukkur, Khanewal, Kohat,
Shahinabad, and Kotri. The first factory was established in Sukkur in 1967, and the other
four factories were opened between 1979 and 1981

Future Restructuring
In March 2010, the Pakistani government announced plans to privatize Pakistan
Railways and split it into four businesses focusing on passenger operations, freight,
infrastructure, and manufacturing. In February 2010, "Unbundling" was proposed the
previous month, with activities being outsourced, privatized, or operated separately.
However, complete privatization has been ruled out.
New lines
New rail lines have been proposed by Pakistan Railways to connect Gwadar Port to
Central Asia, including:
 Karachi–Gwader Railway Line (Makran Railway)
 Gwadar–Mustang Branch Line
 Basima–Jacobabad Branch Line
 Boston–Zhob–Dera Ismail Khan Branch Line
 Islamabad–Muzaffarabad Branch Line
 Jhang Sadar–Risalewala Branch Line

Chapter 2
My training schedule

Chapter 3
Work experience
Training Week 1
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 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
We compiled our attendance sheet by signing it
from foreman and submitted to clerk office in
Diesel classified shop
Training Week4
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 5
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.
Training Week 6
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 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.
Training Week 8
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 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.
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.
Training Week 10
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 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.
foreman and submitted to clerk office in Power plant
shop.
Training Week 12
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 13
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.
Training Week14
I learned the safety factor of roller bearing shop.
foreman and submitted to clerk office in roller
bearing shop.
Training Week 15
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.
Training 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.

Training Week 17
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 method 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.

Chapter 4
DIESEL CLASSIFIED REPAIR
SHOP
Dismantling of Locomotive
After handing over the locomotive, first of
all, the nut bolts that connect the body and
the trucks are open. Then the body of the
locomotive is lifted and then the bogies are
separated. The body of locomotives is lifted
over the stand and dismantledthe trucks. The motor dismantles from
the wheels and sent to the rewinding shop for overhauling themotors.
Dismantle the locomotive wheels and sentto the wheel shop for
machining and inspecting.
The responsibility of the diesel classified workshop is overhauling all
locomotives of Pakistan Railways after every 5 years. 5 different
sections are working for diesel classified.
 Power assembly section.
 Nozzle, fuel Injection & pump section.
 Governor section.
 Electrical section.
 Air compression section.
 Bogie assembly section
 Turbo supercharger section
LUBRICATING SYSTEM
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, theoil returns to the lube oil
system through a return pipe. Oilseals are provided on both the
Lifting of Loco

turbine and blower ends ofthe bearings to prevent oil leakage to the
blower or the turbine housing.
Engine Fuel injectors
Diesel fuel from the injection pump enters the mechanicalinjector
body and starts to build pressure. Once the pressure is high enough
(about 4,000 psi), a check valve in the injector is lifted off its seat,
and fuel sprays through. Diesel fuel injectors are quite complicated;
the injector has a high micron filter on the top inlet side which
corresponds to small hypodermic-sized holes on the bottom for the
atomizing of the diesel fuel.
Traction motor
Traction motors are powered by electricity and generate the power to
rotate the wheels of the train. The turning force produced by traction
motors is transmitted to the wheels via thedriving gear unit and axle.
Traction motors are typically mounted in the trucks where the wheels
are housed.
Cooling system
A locomotive radiator system primarily cools the air, water, and oil.
The air is used in the combustion process; the water for cooling the
engine and turbo (ifequipped); and oil for lubricating the engine
components.

Prime Mover
The ignition of diesel fuel pushes pistons connected to an electric
generator. The resultingelectricity powers motors connected to the
wheels of the locomotive. A “diesel “internal combustion engine uses
the heat generated from the compression of air during the upward
cycles of the stroke to ignite the fuel.

Locomotive and Diesel Engine Parts:
 Wheel for Locomotives.
 Pistons.
 Piston Connection Rod.
 Piston Assembly.
 Piston Ring.
 Engine Bearing.
 Crankshaft.
 Exhaust Valve.
 Engine Gears
 Fuel Injectors
Bogie assembly section
Loco is provided with a fabricated bogie. This
is a three-axle, two-stage suspension with
helical coil springs in the primary stage and
rubber compression springs in the secondary
stage of suspension & a floating type center
pivot arrangement. The bogie frame s hall be
fabricated box type construction, manufactured
from steel plate to IS.2062 grade ‘C”.
The locomotive car body weight is transferred
directly to the bogie frame through four rubber “Compression” spring assemblies. The
bogie frame is supported through a “softprimary” suspension consisting of eight pairs of
helical coil springs (inner & outer). Two
springs are mounted on each equalizer, to provide ride quality and equalization of wheel
setloads.

Locomotives for overhauling
Periodic and accidental maintenance of locomotives
Accidental LocomotiveYearly outrun table

Wheel Assembly
This is the part of a rake that is just adjacent to the tracks. It consists of four main parts:
 Wheel
 Axle
Bearing and Housing
COMPONENTS OF WHEEL AND AXLE ASSEMBLY
 Two brake disks (4), diameter 640 mm and
 Width 110 mm.
 Inbuilt slack adjusting brake cylinder fitted
 Two-wheel disc of tread dia 915 (New), 845 (worn).
Wheels Dismounting Machine
Rialto’s Type a Wheel set Press-Fitting (Mounting, Assembly, or Charging) Machines
used for unloading and assembling wheels, brake discs, and gear wheels. It can be used on
passenger cars, wagons, electric multiple units, and city rail vehicles.

ADVANTAGES OF SUPER CHARGED ENGINE
 A super charged engine can produce 50 percent or more power than a
naturally aspirated engine. The power to weight ratio in such a case is
much more favorable.
 Better scavenging in the cylinders. This ensures carbon free cylinders and
valves, and better health for the engine also.
 Better ignition due to higher temperature developed by higher
compression in the cylinder.
 It increases breathing capacity of engine.
Classification of railways locomotives:
Pakistan railways classified their locomotives in H.P (horse power) and every locomotive
iscalled 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

Primary suspension:
Primary suspension is implemented by two units of two steel coil springs (internal (4) and
external (5)) laid out on the control arm upper part (13) by a centering disk (8) and
adjustment shims, (if required).
The suspension is also completed by the following components:
A control arm (13), fitted with twin-layer elastic joints (12), connecting the axle bearing to
the bogie frame and transmitting, not stiffly, lateral, longitudinal and part ofthe vertical
forces;
A vertical damper (14).
Rubber elements (2) separate the primary suspension from the bogie to realize noise
reduction. Stops and protections are mounted on the bogie frame for the lifting.
 Bogie frame
 Rubber disks
 Centering disk
 Internal spring
 External spring
 Bump stop
 Shim
 Centering disk
 Control Arm Lower Part
 Plate
 Block

E & DC 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
In this shop all parts related to diesel engine are prepared and machinedHere 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

Oil seals
Oil seals – often called grease, fluid or dirt seals
– close spaces between stationary and moving components in mechanicalequipment,
helping prevent lubricant escape. They also stop harmfulcontaminants from entering
machinery, particularly in severe
Environments.
Friction plate
A clutch is a mechanical device that engages anddisengages power transmission,
especially from the driving shaft to the driven shaft. In the simplest application, clutches
connect and disconnect two rotating shafts (drive shafts or line shafts). In these devices,
one shaft is typically attached to an engine or other power unit (the driving member) while
the other shaft(the driven member)
Provides output power for work. While typically the motions involved are rotary, linear
clutches are also possible. In a torque-controlled drill, for instance, one shaft is driven by a
motor and the other drives a drill chuck.
Shell Bearing
Shell bearing is a type of bearing used for mainbearings and big-end bearings, consisting
of a circular housing which can be divided into twohalves thin shell bearings are
Used for most bearing applications in the main engine. They consist of a steel backing
strip coatedwith a layer of white metal Bearings.

Lathe machines
A lathe is a machine tool used principally for shaping articles of metal (and sometimes
woodor 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.
Milling Section
Milling is the machining process of using rotary cutters to remove material[1]
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
individualparts 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.

Grinding Machine
Grinding machines are also regarded as machine tools. A distinguishing feature of
grindingmachines is the rotating abrasive tool. A grinding machine is employed to obtain
high accuracy along with the very high class of surface finish on the work piece.
A grinding machine, often shortened to grinder, is any of various power tools or machine
tools used for grinding, which is a type of machining using an abrasive wheel as the
cutting tool. Each grain of abrasive on the wheel's surface cuts a small chip from the work
piece via shear deformation. Grinding is used to finish work pieces that must show high
surface quality (e.g., low surface roughness) and high accuracy of shape and dimension.
Grinding of Crank Shaft
Fitting Section
Working on components with hand tools and instruments, mostly on workbenches is
generally referred to as 'Fitting work'. The hand operations in fitting shop include
marking, filing, sawing, scraping, drilling, tapping, grinding, etc. Usinghand tools or
power operated portable tools.

TOOL SHOP
A machine tool is a machine for shaping or machining metal or other rigid materials,
usuallyby cutting, boring, grinding, shearing, or other forms of deformation. Machine
tools employ some sort of tool that does the cutting or shaping. 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
 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
toolmaterial depends upon various factors. They are:
 Design of tool
 Production volume
 Rigidity and condition of the machine tool
 Physical and chemical properties of job materials

Milling Section
The milling machine removes material from a work piece by rotating a cutting tool (cutter) and moving it into
thework piece. Milling machines, either vertical or horizontal, are usually used to machine flat and irregularly
shaped surfaces and can be used to drill, bore, and cut gears, threads, and slots.
Lathe Section
Lathe machine term as "mother of machining tools," lathes can be used for a variety of
purposes. These include shaping, drilling, sanding, knurling, turning, cutting, and
deformation. This kind ofversatility in a tool is hard to beat, and that's why so many metal-
and woodworkers depend on lathes for the basis of their work.

Grinding Section
Tool grinding is a subset of the larger field of grinding. It involves a machining-based
productionprocess using abrasives or grinding wheels to produce or re-sharpen a workpiece.
Fitting Section
Fitting involves certain amount of bench work using hand tools or power operated tools. The
variousoperations involved in fitting are filing, marking, sawing, chipping, drilling, reaming,
tapping, etc.

Die Section
A die is a specialized tool that frequently employs the use of a press to shape or cut materials
forcomponents, parts, and machinery. These dies are usually customized to meet the exact
specifications of whatever item they're creating.
Numeric Control Machine

Rehabilitation shop
The first shop I visited was the Rehabilitation shop. Apart from repairs there is also
occasional maintenance.
Supervisory Work in the Rehabilitation Shop:
My duties at the repair shop are to look at loco motivation engine repair tests and to check
outthe cart frame and other different tests .After a crash and a train accident all the
replacement trains are in a repair shop.
I am working is this shop under the supervision of Sir Manzor who is the CIR in the
Locomotive Workshops. They guide me through my internship period which I spend in this
shop are:
 Scheduling Process of Pakistan Railway Engines
 Inspection and checking of I beams
 Inspection and welding of Welded spots in engines
 Inspection of Batteries use in Loco engines
Two different sections are working for diesel classified Rehabilitation shop.
 Assemble and Disassemble Section of Steam and Diesel Locomotivess
 Maintenance/Repair Section
Disassemble Section:
In the section nut and bolts that connect the body and the trucks are open then bogie and rail
body disassemble and lifted by crane. Lifting Crane can bear 150 tone Wight. Two crane-
lifts the body together.

Bogie of Locomotive
Bogie is play an important rolls for the link of rail body and track for the safety and comfort
purpose of passenger. In technical terms bogie called chassis or frame work consisting a
wheelattach to a rail vehicle.
Bogies serve a number of purposes-
1. To support the rail vehicle body.
2. To run stably on both straight and curved tracks.
3. To ensure ride comfort by absorbing vibrations and minimizing centrifugal forces when
the train runs on curved tracks at high speeds.
4. To minimizes generation of track irregularities and rail abrasion

Main Component of bogie are fellow
 Bogie is frame itself.
 Brake components
 Suspension to absorb shocks between bogie frame and rail body.
 Two Wheel set with axle at each end and one at the center.
 Traction Motor
Central Pivot
The central pivot is located on the front side of the frame to allow for a certain level of
rotationof the train. Pivot carries about 60% of direct load and acquires and transmits gravity
and braking. The pivot bowel and loading area are lined with grease for its line. The middle
pivot is checked for appearance. The central pivot pin connects the body to the bogie and
transmits the bogie 'gravity and brakes. It has silent rubber trees that help keep bogies in line
with the body and control and reduce angular oscillations of the bogies to some degree.
Traction Motor:
Traction motor is one of the key features of a diesel train, which plays a key role in the
smoothrunning of the train. The function of the locomotive engine is to convert electrical
energy into mechanical power around the train wheel. The transfer of equipment is not
recommended / incorrect on the train due to the size and weight of the train, the gears large
enough to control it can be too large and too large to operate.
Hand on Skills In Rehabilitation Shop Pre-Inspection:
It is the inspection in which all the pipe fittings, brake equipment are properly fitted and in
placed before starting of testing the following:
 Test for Pressure switch.

 Emergency Application
 Reservoir Charging.
 Release full Brake Application Full Brake Application.
 Sealing Test
 Test for Pressure switch.
 Device
 Release emergency Brake application.
If there is any part is missing or is in damaged condition then it is reported on the inspection
form
Final Inspection
Final testing is one of the most important parts of a bogie and coach care because if there is
adisagreement, the wrong combination or size is gone or a little tolerable so it can beat big
risk. To avoid such an accident, a final examination should be done carefully.
Project Carried Out in the Rehabilitation Shop
Rehabilitation Maintenance Loco Engines
Rehabilitation maintenance of loco engines has two major schedule types:
1. Preventation Maintenance
2. Schedule shed Maintenance
Preventive Maintenance of the PR Locomotives
The efficiency of trains depends on the reliability and availability of trains. Proper and
efficient train maintenance is the foundation of cost-effective train operations. Care
procedureshave emerged from the basic principle that the necessary attention should be paid
to all assets before they deteriorate due to aging which makes them prone to failure. This is
known as maintenance retention. Train block maintenance can be broadly divided into two
headings, namely, periodic adjustments and schedule adjustments.

PR Steam and Diesel Locomotives
The life expectancy of steam and diesel trains is 40 and 36 years, respectively. Due to the
longevity of life, it is important that both assets are stored properly and periodically to
ensurethat there is no deterioration in their condition. The maintenance of steam and diesel
trains isdone as follows.

Schedule shed maintenance of PR Locomotives
Various test schedules have been developed as part of protective care so that specific
sections and parts oftrains can be given need-based attention from time to time. Test
schedules list all the various aspects that need to be taken into account during repair,
depending on the aging and tear parts. The total number of kilometers that should have
been done before these tests were also specified:
Steam locomotives Table 24.6 outlines the various types of schedules approved for the maintenance
of steam locomotives based on the total distance in kilometers covered by the locomotives
Type of
schedule
km covered by WP/WG km covered by YP/YG
Schedule I 1600 950-1100
Schedule II Every month -
Schedule III 24,000 20,000
Schedule IV 48,000 40,000

Diesel locomotives A trip (or weekly) schedule, a fortnightly schedule, a monthly schedule, a
three-month schedule, a six-month schedule, a yearly schedule, a three- year schedule, and a
six-year schedule (POH) have beendrafted for diesel locomotives.
These repair programs are based on experience and informed investigations into the causes
oftrain crashes. Compared to a railroad track, the diesel pump unit is much more complex,
often incorporating an indirect control system with many additional components. As a result
of thisgreat complexity, there is a great deal of inefficiency on the failure of a particular
component.Therefore, in order to ensure a high level of reliability, various schedules have
been developedfor testing and maintenance. The 'service' of small schedules, that is, travel,
two weeks, monthly, etc., which includes routine tests, a little attention, and the like, takes
about 4 to 12 hours. Larger schedules take longer, lasting 6 to 14 days, as they require
major repairs and replacement.

Electric Locomotives
The schedules for inspection and checks given in Table 24.7 are generally followed on
Pakistan Railways to ensure the proper maintenance of electric locomotives.
Table 24.7 Schedule of maintenance of electric Locomotives
Frequency Code Time period alloted
for completion
Nature of attention
Weekly/trip
(within 1500 km)
Trip 1 hr. Weekly or trip inspection
15 days Fortnightly 1 to 2 hrs. Fortnight inspection
Monthly IA 2 hrs. Incidental inspection
Two months IB 8 hrs. Complete/partial inspection
Four months IC 8 hrs. Complete inspection
Every third IC AOH 16 hrs. Annual inspection
At 300,000 km or
after 3 years
IDH 15 days General inspection or intermediate
overhauling
At 600,000 km or
after 6 years
POH 30 days Through overhauling or periodical
overhauling
The frequency and duration of the various schedules are defined after considering the failure
of several trains, the presence of indigenous parts, and the air and dust temperatures in the
country have been considered. Compared to steam and diesel trains, electric trains include

more contacts, relays, and appliances / equipment. Electrical values and changes in the
locomotive state are not physically visible. Therefore, it is important

to check equipment, contacts, and relays periodically to determine the condition of various
equipment without much disruption. Most machines are tested during a four- month test,
therefore, these devices are not included in the annual test. During such inspections,
equipmentis disconnected from mechanical equipment, assemblies are stripped and cleaned,
and worn or damaged parts are replaced and reconnected.
Travel or weekly or bi-weekly assessments are conducted in outdoor work areas, and all
otherschedule assessments, with the exception of POH, are conducted in sheds. POH,
however, is practiced in workshops.
Rolling Stocks
Rolling stock includes locomotives, passenger coaches, goods wagons, and all other types of
coaches & wagons such as electric multiple units (EMUs), diesel rail cars, and special
wagonssuch as BOX wagons. This section gives some of the details of passenger coaches
and goods wagons.
Classification of railways locomotives
Pakistan Railways classifies locomotives according to horse power, and each locomotive
hasits own code number assigned by P.R.
Following is a list of locomotives, along with their numbers.
3000 H.P V-type 16 cylinders’ locomotives
• 8200 two stroke engine • 4700 two stroke engine • 6000 two stroke engine • 6100 two
stroke engine
2000 H.P V-type 12 cylinders’ locomotives
• 5001 four stroke engine • 4800 four stroke engine • 4000 two stroke engine • 8000 four
stroke engine • 6200 two stroke engine
1200 H.P V-type 6 cylinders’ locomotive
EMD 645

The EMD 645 is a diesel engine series developed and built by General Motors' Electro
MotiveDivision. One 16-cylinder v type engine was included in the 645 series, which was
designed primarily for locomotive, marine, and stationary engine applications.

ENGINE CONTROL UNIT
In the Power Device Section, the Engine Control Unit (ECU) is available (PDC). The ECU
isin charge of the diesel engine under various conditions. When required or ordered by an
engine management system, the ECU also protects the diesel engine from serious damage by
using speed protection and power reduction.
The key functions of the ECU are as follows
 Engine speed control
 Acceleration and reduction of the limit
 High fuel limit
 Engine mode control (screaming, running, shutting down, idleness, suspension,
stopping and over speed)
 Favorite speed of engine protection, overcrowding, smoke, low oil pressure and
low water pressure)
 Time management
 Diagnosis.
If certain engine parameters are found outside of the Locomotive Diesel and are operational,
the ECU monitors and detects them. The diesel train is an independentelectric train. Diesel
trains operate on the same basis as electric trains in that the crank shaft of a diesel engine
rotates the alternator. They also have electric drive in the form of traction motors that drive
axles and are controlled by electronic controls. Many auxiliary train systems for cooling,
lighting, heating, and braking are also available. It can be called by the same people. The
power station is made up of a large diesel engine and an alternator that produces the required
electricity. A capacity of 1000 liters of fuel is required. Because diesel engine cannot pull a
train without a large number of gears and collision losses, it is not possible to drive a train
without the use of electric motors. Pakistani railways use trains.
LOCOMOTIVE EVERSPEED
If the train exceeds the maximum allowable speed (122 kph), a Penalty brake application is
initiated until the train speed is sufficiently reduced.

Problems Encountered
 Following Problems we face in this shops are:
 Not properly doing scheduling of the engines
 Not properly welded of the battery racks (where batteries are fitted inside the
locomotives)
 If it is not properly welded then battery is not working properly or not be fitted.
 Not proper Leveling of the Beam facing problem.

Problems Solving
 In-time scheduling maintenance of the engines.
 Proper welded of the Battery racks
 Proper Leveling of beam under manufacturing methods.

Safety at Work
The Pakistan Railway workshop is not following any OSHA rules and other
safety procedures. Workers working in during welded without using any
helmet and propergloves.
 In this shop they are not sun glasses for
workers to prevent the eyesfrom metal chips.
 There is no fire extinguishers and emergency exit in the rehabilitation
shop
 Workers are working without safety shoes and gloves.
 Many their points that can cause of harm of
persons and the propertyalso. The safety at
work is very important.
Work Experience in Rehabilitation shop
The main task of the rehabilitation shop is to repair or rehab damaged
locomotives so that they may be used again. We work with Mr. Mansoor, the
foreman, who informs usabout all of the primary functions of the
rehabilitation shop and its sections. We also visit some of the accident
locomotives and study the locomotive engine's traction motorand cooling
system. We see how they separate the locomotive's pivots from its bogie and
elevate the locomotive's body using a 40-ton horizontal puller crane before
resting it on ground fixed jacks.

FOUNDRY SHOP
In 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. 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 timeto make that part are
mentioned on work order. Operation is performed according to the sequence mentioned on work
order.
Foundry shop is divided in two parts:
 Brass foundry
 Iron foundry
Parts prepared in brass foundry
There are following parts are prepared in this shop
 Sliding door handle
 Upper birth handle
 Coat hook
 Window catcher
 Window stopper
 Window panel
 Glass stand
 Motor cover
Parts prepared in iron foundry
There are following parts are prepared in this shop
 L.P cylinder for D.E loco
 H.P cylinder for D.E loco
 Oil tank cock body
 Disc brake
 Brake shoes
 Caps for alternator body
 Brake block

 Plug for oil tank cock body
CASTING:
Casting is a manufacturing process in which a liquid material is usually poured into a mold,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 molto complete the process.
Casting materials are usually metals or various cold setting materials that cure after mixing two or
more components together.
The following are the basic operations of casting process:
 Pattern making
 Mold preparation
 Melting the metal
 Pouring it into a previously made mold which confirms to the shape
of desired component.

Mold Preparation:
A mold is formed into the geometric shape of a desired part. Molten metal is then poured into the
mold. The mold 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, molds can be classified as either open or closed. An open mold is a container, like a cup,
that has only the shape of the desired part. The molten material is poured directly into the mold
cavity which is exposed to the open environment.
Sand used in molding process
Different types of sand used in brass and iron foundry
Green sand mold :
A green sand mold is composed of mixture of sand, clay and water.
Dry sand mold :
Dry sand molds are basically green sand molds with 1% to 2% cereal flour and 1%to2% pitch.
Place brake pads mold in Sand
The first step of brake pads involves the placement of the mold pattern in sand. The size and
shape of the shoe is directly influenced by the mold. Therefore, must create new molds to create
metal products and components in specific sizes and shape.

Pouring of Molten Metal
Now it’s time to pour the molten metal into the mold cavity. There used metal for break shoe is mild.
Once the metal or alloy has turned from a solid state to a liquid state, it’s poured into the mold cavity.
Fettling Process
Fettling is a process of removing excess material from castings often formed by the die's parting
lines during the casting process when molten material is injected into the die/mold. A process of
removing excess material from casting formed by the divided lines by the casting process.

POWER SHOP
In this shop the piston 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 toutilize in form
of light, fan or Air Conditions. There are two types of generators used in power van. One is 300
KVA which is used in a combination of two generators and 500

KVA 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 an auxiliary tank. Power Van has usually two people for operationat a time during
working. A control panel is used to control both generators while operating.
 Periodic Over Hauling POH
 Complete repairing of carriage/ power van
 NRM & NRE (Nominated Repair) Mechanical/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,
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. The main tank can be from different ranges but mostly used a 3000-liter capacity
tank. Trainload may vary from 3A to 55A, from normal to peak load. In some cases, a generator
of 75 KVA is also placed for extra load or if the load is very less than 75 K VA generator is used.

Following Diesel Engines are used in power vans for generating electricity:
 Perkins
 Caterpillar
 Cummins
Parts of a Diesel Generator:
Diesel generator has many parts but some main parts are below:
Diesel Tank: It is also called auxiliary tank in which diesel is placed for the supply of generators.
Both generators have their own auxiliary tank which is connected with main
tank and a motor is used to supply diesel from main tank to auxiliary tanks.

Fuel Water Separator: Fuel water separator is used to separate water from fuel and prevent
water to flow in engine and prevent engine from rusting.
Fuel Filter/Oil Filter: It is used to filter the fuel from dust particles and other materialwhich may
be harmful and impure.
Actuator: On a diesel engine, actuator is normally used to refer to the actuator in the fuelsystem
which controls the amount of diesel fuel injected into the engine.
Engine: A four-stroke engine is used in diesel generator. A diesel generator is
basically machinery that converts the chemical energy in diesel to electrical
energy. It does this using a diesel engine and an AC alternator, coupled together. Normally
caterpillar and Cummins company’s components are used in it.
Lube oil Filter:
Lube oil is basically oil which is used in moving parts to prevent friction and heat produced by
friction and this filter is used to remove dust particles and impurities from its.

Primary Lube oil pump: It is a pump which is used to pump lube oil in moving parts toprevent
friction and heat produced.
Coolant tank: Coolant tank is a tank which consists of coolant material which is used to reduce
heat in engine and it provide coolant in this regard. Normally distillated water is usedfor coolant.
Radiator & Fan: It is another important part of diesel generator. The radiator on a diesel
generator is the part that transfers the heat from the engine coolant to the surrounding air.When
working correctly, this process keeps the engine from overheating.
Turbo Charger: A turbocharger increases an engine's compression byblowing extra air into the
combustion chamber. The higher air mass allows more injected fuel to be burned. It alsohelps to
outflow carbon dioxide produced in engine.
It is not painted normally because of very high temperature of it.
Silencer: It is used to reduce the noise of the generator. It is connected with engine andplaced at
the top of generator. It is also help in filtering.
Coupling: We use coupling to joint engine and alternator’s rotor. So both engine andAlternator
can rotate together.
Alternator: It is used to produce electricity. In DG, brushless alternator is used. There aretwo
main windings in it, a stator and a rotor winding.
Automatic Voltage Regulator: It is very important and used to regulate voltage and helps
to remain it in a fix level.
Exciter: AVR commands exciter to regulate voltage in for a specific level and exciter worksto
make it on a specific level.
Battery: Normally 2 batteries are used in series in Diesel Generator. And usually it is usedin
couples for example 2, 4 or 6. They are connected in series to produce a 24v supply. It isused to
supply crank motor in starting.

Crank Motor: Crank is used to rotate DG’s rotor in starting. It works until rotor picks up 90% of
the speed. After that motor get stops and engine’s rotor rotates alternator’s rotor. Bythe use of
crank motor and battery, engine will be self-start.
Governor: Governor is used to maintain speed of the rotor even if the load is changing so it
prevent the effects of changing RPM speed which is required to produce 50Hz frequency.
Flywheel: Flywheel is connected on rotor. When rotor rotates on a specific RPM (normally
1500 is required), even if there is changing in load, flywheel is used to maintain the speed of
the rotor.

Control Panel:
Control Panel is used to open and close the circuit of the diesel generator to turn on and offits
supply. It is also used to use generators in series in case of overload and change of generator A to
B in case of emergency or any fault.
It is mainly consist of a display on which voltages, amperes, frequency, and output voltage
and other measures can be seen. It is also consisting of alarm circuits which help to notify signal in
caseof any fault.
Circuit Breaker:
Circuit breaker is used as a protection device and helps to break the circuit in case of overload.
Air circuit breaker is used for this purpose here. Normally 800A circuit breaker is used in 500 KVA
diesel generator

HEAT TREATMENT SHOP
Heat treatment is defined as an operation involving the heating and cooling of a metal or analloy
in the solid-state to obtain certain desirable properties without change composition. Theprocess of
heat treatment is carried out to change the grain size, to modify the structure of thematerial and to
relive 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 and corrosion and much more reason.
Heat treatment consists of heating the metal near or above its critical temperature, held for a
particular time at that finally cooling the metal in some medium which may be air, water, brineor
molten salts. The heat treatment process includes annealing, case hardening, tempering,
normalizing and quenching, nitriding, cyaniding etc. Heat Treatment Process Flow Chart Shown
in figure13
Steps in Heat Treating Operation:

Types of Heat Treatment Processes
Eight different types of heat treatment processes are as follows:
1. Annealing
2. Normalizing
3. hardening
4. Tempering
5. Nitriding
6. Cyaniding
7. Carburizing
8. Flame hardening

Types of Heat Treatment
Annealing
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 softeningprocess.
Heating of from 30 - 50°C above the upper critical temperature and cooling it at the 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 beeasily
machined.
Normalizing
Normalizing: 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 critical temperatureand
cooling it in the air.
It improves mechanical and electrical properties, machinability & tensile strength. Normalizing is
the process of heat treatment carried out to restore the structure of normalcondition.
Hardening
Hardening: The main aim of the hardening process is to make steel hard 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 processof annealing.
Tempering
Tempering: When the hardening process hardens a steel specimen, it becomes brittle and hashigh
residual stress. It is an operation used to modify the properties of steel hardened by quenching for
the purpose of increasing its usefulness.

Tempering or draw results in a reduction of brittleness and removal of internal strains caused
during hardening. Steel must be tempered after the hardening process.
The tempering is divided into three categories according to the usefulness of steel required.
 Low-temperature tempering.
 Medium temperature tempering.
 High-temperature tempering.
Nitriding
Nitriding is the process of the case or surface hardening in which nitrogen gas is employed to
obtain hard skin of the metal. In this process, steel is heated in the presence of ammonia
environment.
Due to this, a nitrogen atom is deposited and makes material hard. Induction hardening andFlame
hardening objects are heated by an oxy-acetylene flame.

Purpose of Nitriding
 To harden the surface of the steel to a certain depth.
 Increase resistance to wear and fatigue.
To increase corrosion resistance.
Cyaniding
Cyaniding: In this process, steel is heated in the presence of sodium cyanide environment. Due to
this, carbon and nitrogen atoms are deposited on the surface of steel and make it hard.
Purpose of Cyaniding
 This method is effective for increasing the fatigue limit of medium and small-sized parts such
as gears, shafts, wrist pins etc.
 To increase surface hardness.
 Increase wear resistance.
 To give the clean, bright and pleasing appearance to the hardened surface.
Carburizing
Carburizing: In this process, steel is heated in the presence of carbon environment. Due tothis
carbon atoms are deposited on the metal surface and make it hard.
Case hardening or surface hardening

Purpose of Heat Treatment of Steel
The following are the purposes of heat treatment.
1. To improve mechanical properties such as tensile strength, hardness, ductility, shock
resistance and resistance to corrosion.
2. Improve machinability.
3. To relieve the internal stresses of the metal-induced during cold or hot working.
4. To change or refine grain size.
5. Improve magnetic and electric properties.
6. Increase resistance to wear, and corrosion.
7. To increase the surface hardness.
Furnaces
Furnaces used for heat treatment can be split into two broad categories: batch
furnaces and continuous furnaces. Batch furnaces are usually manually loaded and unloaded, whereas
continuous furnaces have an automatic conveying system to provide a constant load into the furnace
chamber.
Railway loco heat treatment shop
Batch furnaces
Batch systems usually consist of an insulated chamber with a steel shell, a heating system, and an
access door to the chamber. Schematic Diagram of Batch Furnaces.
Box-type furnace
A Box Furnace features a vertical lift or swing out door allowing the various sized product(s) to be placed
in the furnace. Box Furnaces are utilized for heat-treating, calcining, curing, annealing, stress relieving,
preheating, tempering, and other high temperature thermal processes. The Box type Furnace figure
showing below

Roller Bearings shop
Roller bearings — also known as rolling-element bearings — are similar to ball bearings in that
they are designed to carry a load whileminimizing friction. However, roller bearings transmit
loads using cylinder rolling elements, rather than balls, to maintain the separation betweenmoving
parts of the bearing.These versatile bearings can contain single or multiple rows of rolling can
significantly improve radial load capacity.Also, the use of different roller shapes can further
reduce friction andsupport both radial and axial loads.
While roller bearings can handle higher loads than conventional ball bearings, 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 labor 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, andmultiple bearing rows
can allow for higher performance to meet specific application needs.
Roller Bearing Types and Applications
Cylindrical roller bearings
These bearings feature rollers that are longer than their diameter, and can tolerate higher loads
than ball bearings. Our cylindrical roller bearings can carry heavy radial loads and are able to be
used in high-speed applications.
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 internalclearances 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. This type ofbearing is shown in
fig.26

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. Needle roller Bearing is shown in figure.27.
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. Taper roller bearings are
availablein inch and metric sizes. The taper roller bearing can be shown in figure no-25.
Roller bearings are used in a wide range of applications, from heavyequipment and machinery to
power generation, manufacturing, and aerospace.

Advantages and disadvantages ofanti-friction bearings:
Advantages:
 Special shielded bearing does not required lubrication again.
 It is easy to replace.
 It has very long life and has very less friction.
 It easy operates on high speed and required less lubrication.
Disadvantages:
 Initial cost is usually high.
 Greater diameter space required for comparable shaft diameter.
 Dirt, metal chips and so on, entering the bearings can limit their life causing early failure.
 Lesser capacity to withstand shock.

MOTOR SHOP
The responsibility of motor shop in carriage and wagon is to repairing and
overhauling of cars, buses, trucks, fork lifter and cranes use for Pakistan
railways.This shop consists of mainly two sections
1. Petrol section.
2. Diesel section.
Automobile vehicles owned by Pakistan Railway are being fixed and
overhauled at the petroldivision. Different types of buses, Lorries, and other
diesel vehicles such as cranes and fork lifters are overhauled in the diesel area.
Working of Diesel and Petrol Engines
The diesel and petrol engines that are used in most cars are highly similar. In
essence, they areinternal combustion engines that work using a two or four-
stroke cycle. In an internal combustion engine, the power cycle is made up of
four phases: intake, compression, power and exhaust. In the intake phase, air is
drawn into cylinder through the opening intake valve. In the compression
phase, the intake valve closes and air is compressed with fuel. At this point,
the mixture of fuel and air is ignited to cause an explosion. It is this explosion
that causes the piston to downwards and drives the crankshaft to produce
motion. This is the power phase. The final phase is exhaust where the spent
air-fuel mixture is expelledout of the cylinder through the opening exhaust
valve so that a new cycle may begin.

Difference
The main difference between diesel and petrol engines is that petrol engines use spark
plugs toignite the air-fuel mixture, while diesel engines rely solely on heavily
compressed air.
As mentioned earlier, Rudolf Diesel found that the temperature of air could be
made to increasehigh enough if it was heavily compressed. The temperature
would rise so high to the point where it could cause the ignition of diesel fuel.
Therefore in diesel engines, air in cylinder would be very heavily compressed,
typically to around14 to 23 times its original volume. In petrol engines, the
compression ratio is generally much lower, because they rely more on the
spark plug to begin the power phase. The compression ratio is petrol engines is
typically around only around 7 to 10, with high performance vehicleshaving
higher compression ratios of up to 13.
DIESEL ENGINE OVERHAULED

A diesel engine, which is an internal combustion engine that uses heat to ignite fuel, has an
average service life of about 10 years.
Diesel engines deliver both power and a high level of performance. But wear
and tear over timeon the engine components can lead to mechanical problems
and performance failure. As you start to notice problems occurring with your
diesel engine, the best way to address them might be by getting an engine
overhaul. This procedure involves taking apart the engine, identifyingfaulty
parts and replacing them, cleaning all the engine components, and then
rebuilding the engine. An overhaul can increase the performance, power, and
longevity of your vehicle. Use this guide to help you decide when to have your
diesel engine overhauled.
If you notice any of these problems, it is very likely time to bring your vehicle
in toget an overhaul immediately:
1. Your engine has spun a rod bearing.
2. Your engine has very low or no oil pressure.
3. Your engine has dropped a valve.
If you notice these symptoms, it is a good idea to talk to a mechanic about the
possibility ofgetting an overhaul:
1. Your engine has high blow by.
2. Your engine is consuming a lot of engine oil or coolant.
3. You have put a lot of miles on your diesel and are getting lower fuel efficiency.
SIGNS YOUR DIESEL ENGINE MAY BE IN NEED OF AN ENGINE

OVERHAUL
1. OIL SLUDGE
2. METAL SHAVINGS
3. INCREASED OIL OR COOLANT CONSUMPTION
4. EXCESSIVE EXHAUST
5. KNOCKING SOUNDS
6. COMPRESSION LOSS
7. HITTING MILESTONES
8. SPUN ROD BEARINGS
9. DROPPED VALVE.
10. TURBOCHARGER FAILURE
11. EXTREME BLOW-BY
12. ROUGH IDLE OR RUNAWAY

Steelshop :-
Introduction:-
Pakistan Railways Steel Shop Mughal pura Lahore was built in 1937. Total
area of steel shop is 29.93 acres, out of which 2.88 acres is covered. It works
under the control of Divisional Superintendent Pakistan Railways Workshop
Division, Mughal pura Lahore. There are three main units i.e. Production,
Supporting and Analysis which consist of different shops such as Furnace
Shop, Foundry shop. Rolling Mills, Millwright shop and Laboratory etc. Total
number of plant and machinery installed in Steel Shop are 318, out of which 90
are out of order and 228 were in working condition at the time of audit. Total
number of employees working in Steel Shop is 1030.
Purpose of Steel Shop:-
Main purpose of Steel Shop is to maintain the supply chain of qualitative
ferromagnetic components/products, by adding value through metallurgical and
heat treatment processes to the ferromagnetic scraps. It is the responsibility of
Steel Shop to manufacture components/products on demand in respect of locos,
carriages and wagons, central laboratory in economical and efficient manner
Typically Pakistani railway steel shop can be perform into two method
1: chemical testing
2: Mechanic/ physical testing
Chemical testing perform into two way in railway central laboratory
1: conventional testing
2: spectrometer

Conventional Laboratories:-
The materials department facilities of following conventional labs.
Metallography Lab
Optical Microscopy Lab
Mechanical Testing Lab
Heat Treatment Lab
Hardness Testing Lab
Corrosion Lab
Non-Destructive Testing Lab
Joining of Materials Lab

Computer modeling and Simulation Lab
Sample Preparation Lab
Hydrogen Generation Lab
Nano-Materials Lab
Spectrometer:-
A spectrometer is a scientific instrument used to separate and measure spectral
components of a physical phenomenon. Spectrometer is a broad term often used
to describe instruments that measure a continuous variable of a phenomenon
where the spectral components are somehow mixed. In visible light a
spectrometer can separate white light and measure individual narrow bands of
color, called a spectrum. A mass spectrometer measures the spectrum of the
masses of the atoms or molecules present in a gas. The first spectrometers were
used to split light into an array of separate colors. Spectrometers were
developed in early studies of physics, astronomy, and chemistry. The capability
of spectroscopy to determine chemical composition drove its advancement and
continues to be one of its primary uses. Spectrometers are used in astronomy to
analyze the chemical composition of stars and planets, and spectrometers gather
data on the origin of the universe.

Examples of spectrometers are devices that separate particles, atoms, and
molecules by their mass, momentum, or energy. These types of spectrometers
are used in chemical analysis and particle physics.
Mechanical Testing:-
Mechanical testing is the testing of a material to find out its mechanical
properties, for example its yield strength or hardness. Mechanical testing is
used to ensure that supplied materials will perform as expected.
Tensile test:-
The Tensile Tester TF001, also known as Tensile Strength Tester TF001,
universal testing machine (UTM), universal tensile testing machine, etc.
The Tensile Tester TF001 is used to test the performance of various materials
under tensile, peel, compression, bending, shear, tear, etc.
It is suitable for textiles, rubber, laminated films, packaging materials, pipes,
woven tapes, leather, shoe materials, composite materials, paper, etc. With
different fixtures, the tensile tester can be used to test different materials and
kinds of tests.
TESTEX is a well-known tensile testing machine manufacturer in the industry
and currently sells its products to more than 60 countries and regions
worldwide. Our pull testers are popular worldwide for their good quality as well
as reasonable price.
The Features of Tensile
Testing Machine
1. High testing accuracy, force accuracy ≤ 1%, high test repeatability

The screw is high precision ball screw without backlash, which can do high-
precision tests,
and the surface quenching hardness of the screw is high, so the service life can
reach decades.
2. Designed for 6 different mechanical tests
The tensile Tester TF001 can achieve tensile, compression, bending, tearing,
shearing, and peeling tests.
3. We use 16 test parameters, for a more comprehensive test presentation
The pull testing machine TF001 can show the data of displacement, maximum
force, elongation, stress, maximum stress, bending stress, speed, force width,
thickness, etc.
4. Stable testing process
The tensile testing equipment TF001 is [10:52 AM, 7/31/2023] Ss’ equipped
with a switchable pneumatic tensile fixture, there will be continuous sample
tightening force to reduce sample slippage when conducting the test.
5. Multiple safety settings
We have a built-in intelligent main power supply, a displacement alarm system,

an overload and emergency stop system and up and down stroke limiting sensors,
which keep your equipment safe and stable.
Yield point:-
In materials science and engineering, the yield point is the point on a stress-
strain curve that indicates the limit of elastic behavior and the beginning of
plastic behavior. Below the yield point, a material will deform elastically and
will return to its original shape when the applied stress is removed. Once the
yield point is passed, some fraction of the deformation will be permanent and
non-reversible and is known as plastic deformation.

Chapter 4: 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 is 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. I have Key-pointed my accomplishment as below
• Understood the manufacturing and repairing of Rail Carriages, wagon
boogies, loco Engines & their constituent assembly parts.
• Observed and acquire knowledge about different mechanism dealing with
different machines.
• Applied the theoretical technical knowledge on real industrial applications.
• Built a good rapport & conversational exchange with group of workers and
learn proper behavior of corporate life in industrial sector.
• Enhanced the ability to improve creativity skills and sharing ideas.
• Applied engineering knowledge learned in classroom environment in real

industrial situations.
• Exposed to professional engineering practices in the industries.
• Understood the role and responsibilities and code of ethics that BSc
Engineering technologists should uphold.
• Developed awareness about general workplace behaviors and build
interpersonal skills to prepare professional work records and reports.
• Built rapport and network with probable future employers to increase
employability.

Recommendations:
I would like to give some recommendations to improve the quality of work and
save time along with the health of workers because during our visit we
observed that the
Machinery and equipment used over there was outdated and workers have to
put in more time and effort to diagnose the problems. Up to date machinery
should be installed and modern equipment should be used to increase efficiency
and to save time also. This will also motivate workers to perform their tasks in
a more efficient way.
Need to work on plan to includes building new locomotives, development and
improvement of current rail infrastructure, an increase in average train speed,
improved on-time performance and expansion of passenger services.
1. Need to implement safety measures i.e. wearing safety gloves, safety shoes
and goggles.
2. Need to install temperature gauges to measure the intensity of heat treatment.
3. As belts are used in wide machine operating mechanism therefore, proper
covering should be fenced.
4. Grinding machine needs not to be fully exposed as it could cause severe
hazards.
5. Need to install safety valve to control steam pressure.

Chapter 5: References:
https://agp.gov.pk/SiteImage/Policy/2016-
17%20SAR%20on%20Steel%20shop.pdf
https://www.abc-engines.com/en/markets/engines-
fortraction?gclid=CjwKCAjwi6WSBhA-EiwA6Niok-
pwqvEzNGek1qKDBGsSpKID465R7X8NWuHwNtqqlX9-
kbRnjOeYxoCLpIQAvD_BwE
https://en.wikipedia.org/wiki/Pakistan_Locomotive_Factory
https://en.wikipedia.org/wiki/Pakistan_Locomotive_Factory
https://pk.worldorgs.com/catalog/lahore/gift-shop/carriage-wagon-shops-
pakistanrailways
http://www.sogema-engineering.com/en/our-range-of-products/assembly/
Railway Constructions Pakistan Limited (railcop-pk.com)

Saqib 19AU014 Industry training report.pdf

Recommended

Recommended

More Related Content

Similar to Saqib 19AU014 Industry training report.pdf

Similar to Saqib 19AU014 Industry training report.pdf (20)

Recently uploaded

Recently uploaded (20)

Saqib 19AU014 Industry training report.pdf