Pakistan Railway

2019

INTERNSHIP REPORT
Duration
5 weeks
(23/7/2019-------05/9/2019)

MET Centre
Pakistan Railway Mughal
Pura Lahore (Pakistan)

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PAKISTAN RAILWAY LOCOMOTIVE

WORKSHOPS
LOCOMOTIVES:
A locomotive or engine is a rail transport vehicle that provides the motive power
for a train. If a locomotive is capable of carrying a payload, it is usually rather
referred to as multiple units, motor coaches, railcars or power cars; the use of
these self-propelled vehicles is increasingly common for passenger trains.
DIESEL CLASSIFIED REPAIR SHOP:
In this shop different types of engines come for maintenance in different sections
of this shop. Engines sometimes face problems like extra fuel consumption,
radiator leakage and damages caused by long routes on engine pistons etc.

DISEL ENGINE:
An Internal-combustion engine in which air is compressed to a sufficiently high
temperature to ignite diesel fuel injected into the cylinder, where combustion and
expansion actuate a piston. It converts the chemical energy stored in the fuel into
mechanical energy, which can be used to power freight trucks, large tractors,
locomotives, and marine vessels. A limited number of automobiles also are
diesel-powered, as are some electric-power generator sets.

WORKING OF DIESEL ENGINE:

The diesel engine gains its energy by burning fuel injected or sprayed into the
compressed, hot air charge within the cylinder. The air must be heated to a
temperature greater than the temperature at which the injected fuel can ignite.
Fuel sprayed into air that has a temperature higher than the “auto-ignition”
temperature of the fuel spontaneously reacts with the oxygen in the air and burns.
Air temperatures are typically in excess of 526 °C (979 °F); however, at engine
start-up, supplemental heating of the cylinders is sometimes employed, since the
temperature of the air within the cylinders is determined by both the engine’s
compression ratio and its current operating temperature. Diesel engines are
sometimes called compression-ignition engines because initiation of combustion
relies on air heated by compression rather than on an electric spark.
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STEP BY STEP PROCESS:

TYPES OF DIESEL ENGINES:

By power output
 Small <188 kW (252 hp)
 Medium 188–750 kW
 Large >750 kW
By cylinder bore
 Passenger car engines: 75...100 mm
 Lorry and commercial vehicle engines: 90...170 mm
 High-performance high-speed engines: 165...280 mm
 Medium-speed engines: 240...620 mm
 Low-speed two-stroke engines: 260...900 mm
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By number of strokes
 Four-stroke cycle
 Two-stroke cycle
By piston and connecting rod
 Crosshead piston
 Double-acting piston
 Opposed piston
 Trunk piston
By cylinder arrangement
Regular cylinder configurations such as straight (inline), V, and boxer (flat)
configurations can be used for diesel engines. The inline-six-cylinder design is
the most prolific in light- to medium-duty engines, though inline-four engines are
also common. Small-capacity engines (generally considered to be those below
five liters in capacity) are generally four- or six-cylinder types, with the four-
cylinder being the most common type found in automotive uses. The V
configuration used to be common for commercial vehicles, but it has been
abandoned in favor of the inline configuration.

By engine speeds:
 High-speed engines (> 1,000 rpm),
 Medium-speed engines (300–1,000 rpm), and
 Slow-speed engines (< 300 rpm).
Parts of Diesel Engines:
 Cylinders or Liners
 Nozzles or Fuel Injectors
 Connecting Rod
 Fuel Pump
 Cam shaft
 Crank shaft
 Piston
 Engine Block
 Lube oil

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 Radiator
ENGINES USED IN LOCOMOTIVES:
 16-cylinders Caterpillar Diesel Engine producing 550HP.
 8-cylinders Cummins Diesel Engine producing 450HP, etc.

ELECTRIC and DIESEL COMPONENT SHOP:

In this workshop all parts related to diesel engine are prepared and machined here:

Parts that are machined here are:

 Oil seal
 Friction plate
 Discharge valve
 Valve guide
 Bearing shell

SECTIONS OF E AND DC:

 Grinding section
 Milling section
 Lathe Section

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MACHINES USED IN E AND DC SHOP:
 Hydraulic machines
 Vertical milling machines
 Bench lathes
 Centre lathes

FURTHER PRODUCTIONS OF E AND DC SHOP:

 Suspension Bearings D29 Model (prevents high temperature of axle and is
used in motors)
 Pins V2281 Model (used in making connections)
 Crank shaft (it is made by turning operation, threading operation and
grinding)
 Hub and Gears (used in gear box)
 Water pump shaft (used in air compressors)
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 Re-boring and Re-bushing of connecting rods
 Axial taps (drilling and tapping which used for covering axles)
 Weight rings (used in motors and winding processes)
 Removing of old bushes and fitting of new bushes in bodies of starting
motors)
 Pinion Gutters (used in winding shops)
 High pressure and low pressure pistons
 Maintenance of turbo rotors

FOUNDRY SHOP:
In Foundry shop different types of parts are produced using casting process. After
casting the work pieces are machined to convert them into various parts according
to structure. Various types of furnaces are available at loco shops of railway
industry to cast different number of parts according to demand.

TYPES OF FURNACES:
There are different types of furnaces available at Foundry shop:

 Cupola Furnace
 Tilt Furnace
 Rotary Furnace

CUPOLA FURNACE:
A cupola furnace is a melting device used in foundries that can be used to melt
cast iron and some bronzes. The cupola can be made almost any practical size.
The shell of the cupola, being usually made of steel and has refractory brick. The
bottom is lined with a similar manner but often a clay and sand mixture. It can
hold a temperature of 3000F.

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TILTING FURNACE:
A tilt furnace is also a melting device used in foundries that can be used to melt
aluminum and some bronzes, it is called tilt furnace because we can get molten
metal by tilting the furnace. This furnace can be made almost any practical size.
Temperature for aluminum(550F-600F) and Brass temperature(1050F-1150F).

ROTARY FURNACE:
Rotary melting furnace is very flexible and universal equipment used for
recycling many non-ferrous metals. It is designed according to capacity. In rotary
furnace the required quantity of raw material is filled along with a proportionate
charge of additives. It is used to melt raw iron.

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PARTS MADE IN FOUNDRY SHOP:

BRASS FOUNDRY:
 Sliding door handle
 Upper birth handle
 Coat hook
 Window catcher
 Window stopper
 Window panel
 Glass stand
 Motor cover

IRON FOUNDRY:
 L.P cylinder for D.E loco
 H.P cylinder for D.E loco
 Oil tank cock body
 Disk brakes
 China brakes
 Brake shoes
 Caps for alternator body
 Brake block
 Plug for oil tank
 Hooks
 I-Pads
 Vacuum brake
 Excel collar
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TYPES OF SAND USED IN FOUNDRY SHOP:

 Green sand (River sand+ Water+ Kamoki sand binders)
 Dry sand (Opposite of green sand)
 Molasses sand (waste of sugar mill and is mixture of molasses and dried
river sand)
 Cow-dung sand (cow-dung +water+ kamoki sand)
 Fire clay (Mixture of fire bricks powder)
 Silica sand (For making cores, buffers and plungers)

TYPES OF FOUNDRIES:
FERROUS FOUNDRY

 Carbon is used
 Brick block model V775 used
 Disk brakes are made
 H.P and L.P cylinders are made
 Liver weights are made
NON-FERROUS FOUNDRY:

 No coal is used
 Brass and copper casting is done
 Lead is used
 Tin, Zinc and aluminum used
 No hard cock is used

PAKISTAN RAILWAY CARRAIGE

WORKSHOPS:
MACHINE SHOP:
Machine shop is a large workshop having different machining apparatuses. This
shop includes machines such as milling, boring, lathes, drilling, shaper, planer
and slotter etc. Many machines have three to four tool posts i.e. many jobs could

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be done in less time. Moreover, large components are machined in this shop
which could only be lifted by cranes only. Components included are:

 Engine blocks
 Coupling rods
 Bearing
 Axles
 Rail wheels
 Rail joints
 Fish plates
 Bogie components

MACHINE ANALYSIS:
Some machines were analyzed in detail, such as: -shaper and planner machines,
drilling and boring machine etc. Their structure, parts and working were focused.
The criteria to study every machine is:

 Base
 Table
 Column
 Tool head
 Feed
 Speed

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FURTHER PRODUCTIONS OF MACHINE SHOP:

 Safety Pin B.S 1151
 B.T 527 Bolt
 Bolt for disc B.T 525
 T/Nut D.G 647
 Hand brake T. Nut
 Bogie center Pivot w601
 Center pivot B.T 58
 Buffer spindle
 Buffer plug
 Dummy coupling
 Center pin 22inch
 Master valve rod 7inch
 Draft link
 Floating leaver pin
 Bar locating pin
 Bogie Block
 Floating leaver small pin
 Coupler knuckle pin
 Hager bolt
 Bogie block nut
 T. Bar end

SPRING SHOP:
In this shop all types of springs are produced and manufactured. Springs are
flexible machine element used for controlled application of force or torque or for
storing and releasing mechanical energy.

TYPES OF SPRINGS PRODUCED:

 Buffer spring
 Coil helical spring
 Leaf spring

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SPRING MAKING PROCESS:

 Cut to size
 End Tapering
 Bar Heating (860C-900C)
 Coiling
 Setting of spacing of springs
 Uniform Heating
 Oil Quenching (190C-210C)
 Tempering (480C-510C)
 Scrage Testing
 Grinding
 Painting
Raw material

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Setting Bar Heating

Tempering

Oil Quenching

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Grinding/Finishing

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LIFTING SHOP:
ROLLER AND BEARING SECTION:

 In this section rollers and bearings of rail wheels are examined and repaired
 Fitting of new bearings and rollers are done and damaged rollers and
bearings are removed from rail wheels
 In this section both Chinese and German rail wheels are examined
 Greasing of bearings is done
 Washing of rail wheels and bearings
 Flushing of bearings with white spirit is done
TYPES OF BEARINGS:

 Deep-Groove Ball Bearings

 Angular Contact Ball Bearings
 Self-Aligning Ball Bearings
 Thrust Ball Bearings
 Spherical Roller Bearings
 Cylindrical Roller Bearings
 Tapered Roller Bearings
 Needle Roller Bearings

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PARTS OF BEARINGS:

 Ruler
 Outer
 Inner
 Cage

BEARINGS USED IN COACHES:

 In German Coaches, spherical and tapper bearings are used in their wheels.
 In Chinese Coaches, cylindrical bearings are used.
PARTS OF A RAIL WHEEL:

 Cone (back cover)

 First Bearing
 Distance Piece
 Second Bearing
 Locking Plate
MAIN PROCESS IN ROLLER AND BEARING SECTION:

 Transportation
 Flushing
 Checking
 Greasing (Shell Envenia 3)
 Excel box mounting
 Examination
 End

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CC-16 CHINA SECTION:

 In Chinese under carriage and under frame section, the Chinese trollies and
under frames are examined and repaired.
 There are 3 types of Chinese Trollies:
1. CRC
2. CNR
3. Tancsion
 Chinese bogies contain hydraulic pressure.
 Secondary suspension in the form of circular tubes to damp motion.
MAINTENANCE TARGETS:

 Suspension Tubes
 Disc Brakes
 Springs
 Shocks
 Pivot Pins

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UNDERFRAME SECTION:

 One sole bar is about 72 feet long.

 Bogies are connected by pins and hooks.
 One bogie weighs about 48 tons.
 One underframe of a bogie contains Diagonal bar, Longitudinal bar and a
cross bar.
 German bogies have springs in their buffers.
 Chinese bogies have hydraulic pressure in brakes and shocks.
 One sole bar is about 8 inches wide.
 In this section damaged sole bars and other bars are repaired or removed
when required.

POWER PLANT SHOP:

 Power plant shop is an important railway workshop in which all the work
related to power supply and energy storage is examined.
 Every Rail has one or two power vans to store and generate electricity to
all the carriages or bogies.
 One power van has the capacity to provide electric supply to lights, fans
and ACs of rest of the train carriages.
 Each power van contains 3 engines, with 2 engines (450kw) and 1 of
(150kw).

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WORKING OF A GENERATOR:

An electric generator is a device that converts mechanical energy obtained from

an external source into electrical energy as the output. It is important to
understand that a generator does not actually ‘create’ electrical energy. Instead, it
uses the mechanical energy supplied to it to force the movement of electric
charges present in the wire of its windings through an external electric circuit.
This flow of electric charges constitutes the output electric current supplied by
the generator. This mechanism can be understood by considering the generator to
be analogous to a water pump, which causes the flow of water but does not
actually ‘create’ the water flowing through it. The modern-day generator works
on the principle of electromagnetic induction discovered by Michael Faraday in
1831-32. Faraday discovered that the above flow of electric charges could be
induced by moving an electrical conductor, such as a wire that contains electric
charges, in a magnetic field. This movement creates a voltage difference between
the two ends of the wire or electrical conductor, which in turn causes the electric
charges to flow, thus generating electric current.

Main components of a generator:

The main components of an electric generator can be broadly classified as

follows:
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(1) Engine

(2) Alternator

(3) Fuel System

(4) Voltage Regulator

(5) Cooling and Exhaust Systems

(6) Lubrication System

(7) Battery Charger

(8) Control Panel

(9) Main Assembly / Frame

ALTERNATOR:

The alternator, also known as the ‘genhead’, is the part of the generator that
produces the electrical output from the mechanical input supplied by the engine.
It contains an assembly of stationary and moving parts encased in a housing. The
components work together to cause relative movement between the magnetic and
electric fields, which in turn generates electricity.

 Stator – This is the stationary component. It contains a set of electrical

conductors wound in coils over an iron core.

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 Rotor / Armature – This is the moving component that produces a rotating
magnetic field in any one of the following three ways:
1) By induction – These are known as brushless alternators and are usually
used in large generators.
2) By permanent magnets – This is common in small alternator units.
3) By using an exciter – An exciter is a small source of direct current (DC)
that energizes the rotor through an assembly of conducting slip rings and
brushes.
The rotor generates a moving magnetic field around the stator, which induces a
voltage difference between the windings of the stator. This produces the
alternating current (AC) output of the generator. The following are the factors
that you need to keep in mind while assessing the alternator of a generator:

 Metal versus Plastic Housing – An all-metal design ensures durability of

the alternator. Plastic housings get deformed with time and cause the
moving parts of the alternator to be exposed. This increases wear and tear
and more importantly, is hazardous to the user.
 Ball Bearings versus Needle Bearings – Ball bearings are preferred and
last longer.
 Brushless Design – An alternator that does not use brushes requires less
maintenance and also produces cleaner power.

BLACKSMITH SHOP:
A blacksmith is a metalsmith who creates objects from wrought iron or steel by
forging the metal, using tools to hammer, bend, and cut (cf. whitesmith).
Blacksmiths produce objects such as gates, grilles, railings, light fixtures,
furniture, sculpture, tools, agricultural implements, decorative and religious
items, cooking utensils, and weapons. While there are many people who work
with metal such as farriers, wheelwrights, and armorers, the blacksmith had a
general knowledge of how to make and repair many things, from the most
complex of weapons and armor to simple things like nails or lengths of chain

Smithing process:

Blacksmiths work by heating pieces of wrought iron or steel, until the metal
becomes soft enough to be shaped with hand tools, such as a hammer, anvil and
chisel. Heating is accomplished by the use of a forge fueled by propane, natural
gas, coal, charcoal, coke or oil.

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Forging:

Forging is the process in which metal is shaped by hammering. Forging is

different from machining in that material is not removed by it; rather the iron is
hammered into shape. Even punching and cutting operations (except when
trimming waste) by smiths will usually re-arrange metal around the hole, rather
than drilling it out as swarf.

Drawing:

Drawing lengthens the metal by reducing one or both of the other two dimensions.
As the depth is reduced, or the width narrowed, the piece is lengthened or "drawn
out." As an example of drawing, a smith making a chisel might flatten a square
bar of steel, lengthening the metal, reducing its depth but keeping its width
consistent.

Bending:

Heating iron to a "forging heat" allows bending as if it were a soft, ductile metal,
like copper or silver. Bending can be done with the hammer over the horn or edge
of the anvil or by inserting a bending fork into the Hardy Hole (the square hole in
the top of the anvil), placing the work piece between the tines of the fork, and
bending the material to the desired angle. Bends can be dressed and tightened, or
widened, by hammering them over the appropriately shaped part of the anvil.

Upsetting:

Upsetting is the process of making metal thicker in one dimension through

shortening in the other. One form is to heat the end of a rod and then hammer on
it as one would drive a nail: the rod gets shorter, and the hot part widens.

Punching:

Punching may be done to create a decorative pattern, or to make a hole. For

example, in preparation for making a hammerhead, a smith would punch a hole
in a heavy bar or rod for the hammer handle.

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Combining processes:

The five basic forging processes are often combined to produce and refine the
shapes necessary for finished products. For example, to fashion a cross-peen
hammer head

Welding:

Welding is the joining of the same or similar kind of metal.A modern blacksmith
has a range of options and tools to accomplish this. The basic types of welding
commonly employed in a modern workshop include traditional forge welding as
well as modern methods, including oxyacetylene and arc welding.

Finishing:

Depending on the intended use of the piece a blacksmith may finish.

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