Professional Documents
Culture Documents
UNIVERSITY OF
TECHNOLOGY
PAKISTAN
RAILWAY
MUGHALPURA
Roll No 19AU041
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 correctequipment 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 andcostly equipment problems, eliminate repetitive failures.
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 me to get use
to the railway environment, to interact with its different actors. Plus, it makes me to
evaluate my theoretical knowledge into practical work and it develops a certain kind of
autonomy. Globally, I would say that an Internship develop my capacity to adapt and
complete the courses I follow at the educational institutes Professionally speaking, this
internship has reinforced my interest for a work placement in Production Department asI
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.
I express my sincere thanks to the Senior Section Engineer who helped me through
his expert guidance during this training. Had it not been for his encouragement and
motivation, I would not have seen an honest course of success through this training
course.
After the partition of British India and the independence of Pakistan in 1947,
Northwestern State Railway had most of its infrastructure in Pakistani territory and was
renamed Pakistan Western Railway. In East Bengal, the section 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 km (314 mi) 1,000 mm (3 ft 3+3⁄8 in) meter gauge, and
736 km (457 mi) (762 mi) ft 6 in) narrow gauge.
In 1954, a branch line was extended from the Karachi-Peshawar railway line to
Mardan and Charsada. Two years later, the Jacobabad-Kashmore meter gauge line was
changed to 1,676 mm (5 ft 6 in) broad gauge. The Kot Addu-Kashmore section of the
Kotri-Attock railway line was built from 1969 to 1973, providing an alternative route
from Karachi to North Pakistan. In 1974, the name of Pakistan Western Railway was
changed to Pakistan Railway. In February 2006, the 126-km (78 mi) Hyderabad–
Khokhrapar branch line was converted to 1,676 mm (5 ft 6 in). During the 2000s, all
Vision
Mission
Mission is leading the public and private sector in engineering fields including
railways. Providing the highest quality and safety standards in an economical and
efficient manner.
D.S/W
Dy D.S/W
The Railway Board functioned from 1959 to 2000 and was amended between 2000
and 2014 with the addition of the "Executive Committee of the Railway Board".
However, on 20 February 2015, the Railway Board was reconstituted. Chairman
Pakistan Railway Board Independent Board consists of:
This composition could not be approved by the Parliament and at present the
members of the Board are ex-officio. The Secretary is also the Chairman of the Railway
Board. The Secretariat of the Board is headed by the Secretary Railway Board. The seat
of the Board is Ministry of Railways, Islamabad
Director Estt
(BS-19)
Secretary railway
Board (BS-21)
Director Admin
(BS-19)
Secretary DG Technical
Manister of railway Chairman
Railway (BS-22) (BS-20)
DG Planning
(BS-20)
The success of any transportation project depends on its construction. With well-
thought-out and well-designed stations, cars and other components of a public transport
network, an effective design can attract more users. On all railways, the Design Office
provides the following services:
1. Track design (alignment, positioning, blank line and shift and crossing, gauge
specification) Signal and train control design (scheme development, building
design)
5. Channel design.
The design and painting office is equipped with the latest technology and can
design and arrange any type of stock. During project execution, the design office
provides support to the production department, and any issues are resolved by qualified
design professionals. This office also has a library.
German coaches.
Chinese coaches.
There are some coaches who are designed for a specific purpose.
Power Van: Designed to carry an engine to power appliances and air conditioners.
Karachi Lahore
Multan Peshawar
Quetta Rawalpindi
Sukkur
Major Departments
Factory Area
Schedule of Training
In this chapter, I will look at the details of the workshops and workshops as well as
the training program in the areas where I spent four months of training (16 weeks).
There were several places in the train interviews where I completed my training days
and did various jobs and activities related to the workshop environment.
The role and training program are explained in more detail below. I completed my
8 hours of exercise five days a week as per NTC requirements. Check-in and check-out
times for the workshop are 8:00 am and 4:00 pm respectively. A 2-hour lunch break is
available. There are other job sites where I completed my training which are listed
below:
As a trainee, I have to observe all the working processes at different sites or work
places. My duties are to analyze common faults and their solutions including time
management and other important factors that affect the maintenance process of any
working site.
5. To enhance the ability to improve students’ creativity skills and share ideas.
Foundry Shop
Working Experience
In this chapter, I discuss key learning outcomes from this training as well as other
key components and resources identified in Pakistan Railways workshops across the
country. Many types of manufacturing, production, processing and special purpose
equipment are used in all forums. Everyone knows that all machines work with some
form of energy. Electric power is suitable for control, conversion, and various other
functions.
I participated in workshops, which are listed here, and information about the work
and other related resources for these discussions and venues. The following paragraphs
include a detailed workshop and a quick description of my work in this workspace.
I also work in the central laboratory where I see how to check the materials with the
help of chemical or physical methods and also work on the latest testing machine
spectrometer. I also work on the mechanical testing machines there.
Dismantling of Locomotive
3. Governor section.
1. The wheel
2. Axle
During this test I can get the following indicators for different measurement tests
and different test results:
3. I check the temperature of traction motor during testing with the help of
temperature meter.
4. Temp test (ambient temperature should rise by 20+). If the temperature is 20, that
means add 10 to 20 = 30.
After one year of motor working the motor is dry then I repair it after 1 year.
Note: Throughout this process. This motor uses a hold type chemical to hold the threads
of the nut.
1. Do not overuse silicon during traction motor testing with internal traction motor
problems.
2. Center Pivot Not Welded Properly If it is not properly welded and finished
properly, it is not properly fitted in its position and if it is not in its position If it
does not fit then the train cannot move the specified and proper required amount
of degree 60 as its transfer aids. Trains left or right.
Problems Solving
2. Use the mega meter correctly (adjust the difference before using the meter which is
zero).
I am working in this shop under the supervision of Sir Zahid who is the in-charge in
Diesel Classified Workshops. They guide me through my internship period which I
spend in diesel shop:
2. Overhauling of locomotives.
The workshop of Pakistan Railways is a very practical institution. The best and
most profitable thing is that the workshop is completely free. It requires no external
vendors or manufacturing capabilities. This part is very powerful for railway workshop.
The main objective of a railway workshop is to maintain the locomotives, to carry out
their routine maintenance. The organization is doing its work very well but with old
techniques. Some tips are suggested to increase productivity:
1. Using modern equipment and techniques. For example that in the engine
block shop
2. Still using the old telescope for scoping and alignment. Using modern laser
and graphical techniques can save both time and money.
4. 4. Production shops like forging, blacksmith, spring and casting shop. Can be
used to make external projects and parts. This can increase their profits and
popularity.
Quality management
2. They are using old techniques but working with absolute quality. They have a
proper inspection and testing system. It can be further enhanced by using
modern techniques
1. In this shop they have sunglasses for workers to protect eyes from metal
chips during welding or finishing.
4. Many other points which can also cause damage to persons and property.
Safety at work is very important.
Lathe machines
A lathe is a machine tool used primarily for shaping metal objects (and sometimes
wood or other materials) by holding and rotating the workpiece through a lathe while a
tool bit is inserted into the work. is pushed forward causing cutting action. The basic
lathe that was designed to cut cylindrical metal stock has been further developed to
produce screw threads. Tapered work, drilled holes, knurled surfaces and crankshafts
work are done with this machine.
Milling Section
Milling is a machining process that uses a rotary cutter to remove material from a
workpiece by advancing (or feeding) in one direction at an angle to the axis of the tool.
It covers a wide variety of operations and machines, from small individual parts to large,
Grinding Machines
I am working in this shop under the supervision of Sir Ali who is the in-charge in
E&DC Workshops. They guide me through my internship period which I spend in
E&DC shop:
Workshop of Pakistan Railways is a very useful institution. One of the best and
most profitable things is that the workshop is completely free. It does not require an
external vendor or product. This section is filled with the power of the Railway
Workshop. The main motivation of a train workshop is to maintain the train, to maintain
it from time to time. The organization does its work very well but in a very old
fashioned way. In the process of increasing productivity, some points are raised:
1. Time management and team communication are very important in all fields.
2. The workplace also has a lot of working and production space. Manufacturing
stores like forging, blacksmith, spring and casting shop. It can be used for
external projects and components. This can increase their profits and popularity.
Pakistan Railway Workshop is following any OSHA rules and other safety procedures.
1. In E & DC shop they have sunglasses for workers to protect eyes from metal
chips.
Milling Section
Lathe Section
The term lathe machine is referred to as the "mother of machining tools", lathes can
be used for a variety of purposes. These include shaping, drilling, sanding, curving,
bending, cutting, and deformation. It's hard to beat that kind of versatility in a tool, and
it's why many metal and woodworkers rely on lathes for their work.
Grinding Section
Fitting Section
Fitting involves a certain amount of bench work using hand tools or power tools.
Various operations involved in fitting are filing, marking, sawing, chipping, drilling,
reaming, tapping etc.
Die Section
A die is a specialized tool that often uses a press to shape or cut materials for
components, parts, and machinery. These dies are usually custom made to meet the
exact specifications of whatever item they are making.
I am working in this shop under the supervision of Sir Ahmad who is the in-charge
in Tool Workshops. They guide me through my internship period which I spend in Tool
shop:
1. Working on die.
Workshop of Pakistan Railways is a very useful institution. One of the best and
most profitable things is that the workshop is completely free. It does not require an
external vendor or product. This section is filled with the power of the Railway
Workshop. The main motivation of a train workshop is to maintain the train, to maintain
it from time to time. The organization does its work very well but in a very old
fashioned way. In the process of increasing productivity, some points are raised:
1. Time management and team communication are very important in all fields.
2. The workplace also has a lot of working and production space. Manufacturing
stores like forging, blacksmith, spring and casting shop. It can be used for
external projects and components. This can increase their profits and popularity.
Safety at Work
The Pakistan Railway workshop is not following any OSHA rules and other
safety procedures.
In tool shop they are not sun glasses for workers to prevent the eyes from metal
chips.
1. Preventation Maintenance.
The life expectancy of steam and diesel trains is 40 and 36 years respectively. Due
to their long lifespan, it is important that both assets are properly and periodically stored
to ensure that their condition does not deteriorate. This is how steam and diesel trains are
maintained.
These repair programs are based on experience and informed investigation into the
causes of train accidents. Compared to railway track, a diesel pump unit is much more
complex, often involving an indirect control system with many additional components.
As a result of this great complexity there is a great deal of inefficiencies upon the failure
of a particular component. Therefore, to ensure a high level of reliability, different
schedules for testing and maintenance have been developed. A 'service' of short
schedules, i.e. travel, bi-weekly, monthly, etc., which includes routine tests, small
Electric Locomotives
The schedules for inspection and checks given in following table are generally
followed on Pakistan Railways to ensure the proper maintenance of electric
locomotives.
Travel to external work areas is reviewed either weekly or bi-weekly, and all other
schedule reviews with the exception of POH are conducted in the sheds. POH, however,
is practiced in workshops.
Rolling Stocks
Rolling stock includes locomotives, passenger coaches, goods wagons, and all other
types of coaches and wagons such as electric multiple units (EMUs), diesel railcars, and
special wagons such as BOX wagons. Some details of passenger coaches and goods
wagons are given in this section.
Pre-Inspection
This is the inspection in which all pipe fittings, brake equipment are properly
installed and maintained before starting the following test.
Emergency application
Reservoir charging.
Sealing test
Device
2. Battery racks are not welded properly (where the batteries are mounted inside the
engines).
3. If it is not welded properly then the battery is not working properly or not fit.
Problems Solving
Two different sections are working for diesel classified Rehabilitation shop
Maintenance/Repair Section.
Disassemble Section
In the section, inspection of accident vehicle is to be done. The nuts and bolts that
connect the body and the truck are loosened and then the bogie and rail body are
separated and lifted by a crane. The lifting crane can bear 150 tons of white. Two crane
lifts lift the body together.
Bogie of Locomotive
The bogie plays an important role in connecting the rail body and the track for the
purpose of passenger safety and comfort. A bogie in technical terms is a chassis or
framework containing a wheel that is attached to a rail vehicle.
Brake components.
Two Wheel set with axle at each end and one at the center.
Traction motor.
Central Pivot
The central axis is located at the front of the frame to allow a certain degree of
rotation of the train. The pivot carries about 60% of the live load and receives and
transmits gravity and braking.
The axle's gut and loading area are greased for its line. The median axis is checked
for appearance. The central pivot pin connects the body to the bogie and transmits the
bogie's gravity and brakes. It has silent rubber trees that help keep the bogies in line with
the body and somewhat control and reduce the angular oscillations of the bogies.
The traction motor is one of the main features of a diesel train, which plays a key
role in the smooth running of the train. The job of a locomotive engine is to convert
electrical energy into mechanical power around the wheels of the train. Transferring
equipment on a train is not recommended due to the size and weight of the train, gears
large enough to control it may be too large and too large to operate.
Workshop of Pakistan Railways is a very useful institution. One of the best and
most profitable things is that the workshop is completely free. It does not require an
external vendor or product. This section is filled with the power of the Railway
Workshop. The main motivation of a train workshop is to maintain the train, to maintain
it from time to time. The organization does its work very well but in a very old
fashioned way. In the process of increasing productivity, some points are raised:
Time management and team communication are very important in all fields. The
rail systems are good but need some upgrades to improve their production and crafting.
The workplace also has a lot of working and production space like manufacturing
stores like forging, blacksmith, spring and casting shop. It can be used for external
projects and components. This can increase their profits and popularity.
Quality Management
They use old techniques but they work perfectly. They have a proper system of
testing and evaluation. It can be further developed using modern techniques.
Pakistan Railway Workshop is not following any OSHA rules and other safety
procedures.
In this shop they do not have sunglasses for workers to protect eyes from metal
chips.
Many points that can cause damage to persons and property. Safety at work is
very important.
Coat hook.
Window catcher.
Window stopper.
Window panel.
A mold is formed to the desired part geometry. The molten metal is then poured
into a mold, the mold holding the material in shape as it solidifies. A metal casting is
made. Although it sounds simple, the process of manufacturing metal castings is both a
science and an art. First, molds can be classified as open or closed. An open mold is a
container, like a cup, with only the desired part shape. The molten material is poured
directly into the mold cavity which is exposed to the open atmosphere.
Below you will find the most important foundry worker skills. I ranked the top
foundry worker skills based on the percentage of foundry worker resumes on which they
appeared. For example, 35% of foundry workers' resumes include sand molding as a
skill.
The second most common hard skill for a foundry worker is aluminum
casting which appears on 9% of resumes. The third most common
foundry worker skill is arc welding at 7% of resumes.
Three common foundry worker soft skills are computer skills, dexterity
and physical strength.
Problems Encountered
Problems Solving
CASTING
Casting is a manufacturing
process in which a typically liquid
material is poured into a mold, which
has a hollow cavity of the desired
shape, and then allowed to solidify.
The solid part, also known as a
Figure 19: CASTING
casting, is pulled or broken out of the
mold to complete the process. Casting materials are usually metals or different cold-
formed materials that solidify after two or more components are mixed together. Pouring
liquid metal into a previously made mold which confirms to the shape of desired
component.
Workshop of Pakistan Railways is a very useful institution. One of the best and
most profitable things is that the workshop is completely free. It does not require an
external vendor or product. This section is filled with the power of the Railway
Workshop. The main motivation of a train workshop is to maintain the train, to maintain
it from time to time. The organization does its work very well but in a very old
fashioned way. In the process of increasing productivity, some points are raised:
Time management and team communication are very important in all fields. The
rail systems are good but need some upgrades to improve their production and
The workplace also has a lot of working and production space. Manufacturing
stores like forging, blacksmith, spring and casting shop. It can be used for
external projects and components. This can increase their profits and popularity.
Quality Management
Safety at Work
The Pakistan Railway workshop is not following any OSHA rules and other safety
procedures.
In this shop they do not protect their eyes from light of molten metal.
The main function of a foundry shop is to melt different type of material and from
molten metal they make things like brakes, window handles. I work with Mr. Naim, the
foreman, who briefs me about all the basic operations of the foundry shop and its
sections. I also see how materials melt in a furnace and types of furnace. The melting
temperature of different elements is aluminum melts at a temperature of 350-400°C.
Copper melts at 1100°C.
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 KVA generators is used.
During working in this shop my responsible is to work with the technician. I must have a
strong understanding of electrical systems and be able to troubleshoot problems. There
are 12 skills that every generator technician should possess:
Problems Encountered
Generators overheat.
Missing of generator.
Power van equipped with 2 digi set having capacity 350kVA (for AC or lights load).
Chinese
German
Perkins.
Caterpillar.
Cummins.
Workshop of Pakistan Railways is a very useful institution. One of the best and
most profitable things is that the workshop is completely free. It does not require an
external vendor or product. This section is filled with the power of the Railway
Workshop. The main motivation of a train workshop is to maintain the train, to maintain
it from time to time. The organization does its work very well but in a very old
fashioned way. In the process of increasing productivity, some points are raised:
Time management and team communication are very important in all fields. The
rail systems are good but need some upgrades to improve their production and
crafting.
The workplace also has a lot of working and production space. Manufacturing
stores like forging, blacksmith, spring and casting shop. It can be used for
external projects and components. This can increase their profits and popularity.
Quality Management
The Pakistan Railway workshop is not following any OSHA rules and other safety
procedures.
In this shop they do not protect their eyes from light of molten metal.
There is no fire extinguishers and emergency exit in the Power Plant shop.
The main function of a Power Plant shop is to check the fault of power van and
resolve it for use this again. I work with Mr. Abubakar, the foreman, who briefs me on
all the basic operations of the power plant and its sections. I also look at how overhaul
the generator of power van and power output test of power van generator. Basically 2
companies are use their engine in power van first one is Perkins and second one is
Cummins.
Heat treatment is defined as an operation that involves heating and cooling a metal
or alloy in the solid state to obtain certain desired properties without changing the
composition. Heat treatment is used to change the grain size, change the texture of the
material, and relieve the stress that the material has developed after hot or cold working.
1. Cleaning 1. Heating
2. Prewash with 2. Preheating
Loading coalescence 3. Sock and
3. De-phosphate diffusion
system 4. Pre cooling
4. Spray rinse
1. Tempering 1. Quenching
Unloading (cooling)
2. Surface coating
2. Post wash
Annealing
Normalizing
hardening
Tempering
Nitriding
Cyaniding
Carburizing
Flame hardening
Annealing
Annealing is one of the most important heat treatment processes. It is one of the
most commonly used operations in the heat treatment of iron and steel and is described
as a softening process.
Heating from the upper critical temperature to 30 - 50°C and cooling very slowly
by drawing it from the furnace. The main purpose of annealing is to make the steel more
soft and malleable and to relieve internal stresses. This process softens the steel so that it
can be easily machined.
The main purpose of normalizing is to remove the internal stresses created after the
cold working process. In this, the steel is heated to 30 - 50 °C above its upper critical
temperature and cooled in air.
Hardening
The main purpose of the hardening process is to harden the steel. In this process,
the steel is heated to 30°-40°C from the upper critical temperature and then quenched in
water or oil and continues to cool to room temperature. This is the opposite process of
annealing.
Tempering
When the hardening process hardens the steel sample, it becomes brittle and has a
higher residual stress. It is an operation used to change the properties of the steel being
hardened by quenching with the aim of increasing the steel's workability.
In this process steel is heated in presence of carbon atmosphere. This causes carbon
atoms to accumulate on the surface of the metal and harden it.
To relieve the internal stresses of the metal-induced during cold or hot working.
Workshop of Pakistan Railways is a very useful institution. One of the best and
most profitable things is that the workshop is completely free. It does not require an
external vendor or product. This section is filled with the power of the Railway
Workshop. The main motivation of a train workshop is to maintain the train, to maintain
it from time to time. The organization does its work very well but in a very old
fashioned way. In the process of increasing productivity, some points are raised:
Time management and team communication are very important in all fields. The
rail systems are good but need some upgrades to improve their production and
crafting.
The workplace also has a lot of working and production space. Manufacturing
INDUSTRIAL TRAINING REPORT Page 74
stores like forging, blacksmith, spring and casting shop. It can be used for
external projects and components. This can increase their profits and popularity.
Quality Management
Safety at Work
The Pakistan Railway workshop is not following any OSHA rules and other safety
procedures.
In this shop they do not protect their eyes from light of hot metal.
There is no fire extinguishers and emergency exit in the heat treatment shop.
The main function of a heat treatment shop is to increase or decrease the softness or
hardness of material. I work with Mr. Amjad, the foreman, who briefs me on all the
basic operations of the heat treatment shop and its sections. I also look at how Furness
heat up the material that decrease its hardness. Basically 2 Furnace are used in this shop
first one is Batch furnace and second one is box type.
Engineers will recognize these hazards Figure 24: Betex BPP Puller Pusher, used for
installation and removal of railway bearing sets.
when they encounter stuck wheels or
bearings. Cutting or grinding can be dangerous and damage the shaft. Even installing
parts safely can be a challenge. Having the right tools in a rehab facility should be a
priority to ensure reliability and personal safety.
Bega Special Tools specializes in tools for removing and installing bearings and
other transmission components. A number of tools are specially designed for the rail and
metro business to remove and install railway bearing sets, gears, brake discs, labyrinth
rings, etc.
For removing and installing railway bearing sets and labyrinth rings, special
induction heaters can be used. Mid-frequency induction heating technology is a safe and
cost-effective heating method that improves installation quality. Bega Betex
manufactures various models of the MF Quick-heater, also available with fixed or
flexible inductors.
Specially designed for loading and unloading railway bearing sets, the Betex
BPP/BPPS is a combined bearing puller and pusher.
These bearings have rollers that are longer than their diameter and can withstand
higher loads than ball bearings. Cylindrical roller bearings can carry heavy radial loads
and are suitable for use in high speed applications.
slim cross-section design. These bearings are offered with inch or metric seals.
The Stage 8 cap screw locking system is currently under review by the AAR
WABL (Wheels, Axles, Bearing and Lubrication) Committee, and is to undergo field
testing in unit train service. The Stage 8 cap screw locking system represents the first
innovation on a standard locking plate in over 50 years.
Workshop of Pakistan Railways is a very useful institution. One of the best and
most profitable things is that the workshop is completely free. It does not require an
external vendor or product. This section is filled with the power of the Railway
Workshop. The main motivation of a train workshop is to maintain the train, to maintain
it from time to time. The organization does its work very well but in a very old
fashioned way. In the process of increasing productivity, some points are raised:
Time management and team communication are very important in all fields. The
rail systems are good but need some upgrades to improve their production and
crafting.
The workplace also has a lot of working and production space. Manufacturing
Quality Management
Safety at Work
The Pakistan Railway workshop is not following any OSHA rules and other safety
procedures.
There is no fire extinguishers and emergency exit in the Roller Bearing shop.
The main function of a Roller Bearing shop is to working of the bearings of train
wheel. I work with Mr. Hashim, the foreman, who briefs me on all the basic operations
of the roller bearing shop and its sections. I also look at how to engage or disengage
bearing.
Carriage and Wagon Motor Shop is responsible for repairing and overhauling cars,
buses, trucks, forklifts and cranes used for Pakistan Railways. This shop mainly consists
of two parts:
Petrol section.
Diesel section.
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 provide both power
and high efficiency. But wear and tear on engine components over time can lead to
mechanical problems and performance failures. As I start to notice problems with my
diesel engine, the best way to fix them may be to have the engine overhauled. This
procedure involves disassembling the engine, identifying and replacing faulty parts,
cleaning all engine components, and then rebuilding the engine. An overhaul can
increase the performance, strength and longevity of my vehicle. Use this guide to help
you decide when to service your diesel engine.
The main difference between diesel and petrol engines is that petrol engines use
spark plugs to ignite the air-fuel mixture, while diesel engines rely entirely on highly
compressed air.
As mentioned earlier, Rudolf Diesel found that the temperature of air can be quite
high if it is compressed too much. The temperature will rise to the point where it can
cause ignition of the diesel fuel.
So in diesel engines, the air in the cylinder will be highly compressed, usually
about 14 to 23 times its original volume. In petrol engines, the compression ratio is
usually very low, as they rely more on the spark plug to initiate the power phase. The
compression ratio is that petrol engines are usually only around 7 to 10, high
performance vehicles have a compression ratio of up to 13.
Problems Encountered
If you notice any of these problems, it's very likely that vehicle should be brought in for
an overhaul immediately:
If you notice these symptoms, it's a good idea to talk to a mechanic about the possibility
of repairs:
Put too many miles on your diesel and you are getting poor fuel efficiency.
Workshop of Pakistan Railways is a very useful institution. One of the best and
most profitable things is that the workshop is completely free. It does not require an
external vendor or product. This section is filled with the power of the Railway
Workshop. The main motivation of a train workshop is to maintain the train, to maintain
it from time to time. The organization does its work very well but in a very old
fashioned way. In the process of increasing productivity, some points are raised:
Time management and team communication are very important in all fields. The
rail systems are good but need some upgrades to improve their production and
crafting.
The workplace also has a lot of working and production space. Manufacturing
stores like forging, blacksmith, spring and casting shop. It can be used for
external projects and components. This can increase their profits and popularity.
Safety at Work
The Pakistan Railway workshop is following OSHA rules and other safety
procedures. Workers working in shop with safety rules
The main function of a motor shop is to maintain buses and vehicles of Pakistan
railway workshop. I work with Mr. Shahid, the foreman, who briefs me on all the basic
operations of the motor shop and its sections. I also look at over haul the diesel engine.
Basically 2 sections of this shop first one is petrol and second one is diesel.
The purpose of the Central Laboratory in Pakistan Railways is to test the properties
and behavior of various materials physically or chemically. A variety of parts for metal,
leather, oil, water and chemically different materials
Various materials used in Pakistan Railways are tested in this lab and approved or
rejected.
Tatition method
Conventional Wet method
method Craniometric method
Chemical
testing
Spectrometry
Mechinecal
Yield
testing
Rockwell
Paint section
Diesel testing Alongation
Brennan
Central
Laboratory Greece testing
Oil section
Petrol testing
Water section
Quench oil
testing
Textile section
Non Faros
section
The laboratory conducts various quality tests to ensure that materials used in
railway operations meet the required standards. This may include checking the quality of
fuel, lubricants, construction materials or other items used in rail infrastructure.
Chemical Analysis
Material Testing
The central laboratory is responsible for testing various materials used in railway
operations. This may involve testing structural materials such as concrete, steel or wood
to determine their strength, durability and suitability.
Steel shop
Pakistan Railway Steel Shop Mughalpura Lahore was built in 1937. The total area
of steel shop is 29.93 acres out of which 2.88 acres are covered. It works under the
control of Divisional Superintendent Pakistan Railway Workshop Division Mughalpura
Lahore. There are three main units i.e. production, support and analysis which consist of
various shops like furnace shop, foundry shop, Rolling mills, millwright shop and
laboratory etc. The total number of plant and machinery installed in the steel shop is
318, of which 90 were out of order and 228 were in working condition at the time of
audit. The total number of employees working in the steel shop is 1030.
The entrance slit inside the spectrometer is important because it determines the amount
of light that is able to enter the instrument being measured. This affects not only the
speed of the spectrometer engine (more light can generally result in a faster instrument)
INDUSTRIAL TRAINING REPORT Page 90
but also the optical resolution expressed at full width at half maximum (FWHM) the
smaller the slit size the better its resolution.
Light passing through a narrow aperture has a different natural behavior as it is cut. By
reflecting the divergent beam onto a concave mirror, the light beam becomes collimated:
all the light rays are directed parallel to the diffraction grating. A grating is used as a
dispersive element to disperse the wavelengths of light. The characteristics of the grating
include not only its dispersion range but also affect the optical resolution through the
number of grooves. Another parameter of the grating, its blaze wavelength, determines
the best performance at different wavelengths.
Once the light hits the diffuser, each wavelength of light is reflected under a different
angle (like a prism). Different diffraction gratings can be used to identify different
wavelength ranges. As this beam differs due to the behavior of the grating, a second
concave mirror is used to focus light rays of each wavelength onto specific pixels of the
detector. At this point, the actual ratio of each individual wavelength is converted to
electrons, which are digitized and then output for the operator to read.
All of the above components can be configured in different ways to achieve different
results. For example, the entrance slit can be changed to allow more or less light to enter
the spectrometer, and diffraction gratings come in different types to measure different
wavelength ranges.
Admesy offers a range of spectrometers used for lighting, display and analysis
measurements.
The Neo Series spectrometer is easy to use and provides accurate measurements in a
robust instrument. It benefits from high dynamic range and low noise, due to the high-
The Neo series spectrometer can cover almost any wavelength range in the 250 - 1100
nm range and standard versions, such as VIS and UV-NIR, are available. A variety of
gratings are available for use with the Nu Series to suit many wavelength ranges.
Conclusion
The internship program completed at the Railway Workshops is one of the best
practical experiences ever acquired. Many different tasks are assigned and completed by
me in group and also individually. Basic knowledge about practical circuits working in
industry is covered during the training period. Powerhouse equipment is a major part of
the learning process and I practiced the operating mechanisms with structural models of
each equipment and machinery. The overall experience of working in each workshop
was informative and varied. I learned how to manage the workload at any job site and
gain experience from co-workers. I believe that the practical skills and knowledge
gained from this internship program will definitely help me in my future professional
life. Finally, I would like to thank my teachers and all the people in this organization that
helped me a lot during my internship. I have identified the keys to my success below:
Communicate well with group of workers and learn proper attitude of corporate
life in industrial sector.
To understand the role and responsibilities and code of conduct that a BSc.
INDUSTRIAL TRAINING REPORT Page 93
Engineering Technologist must uphold.
Recommendations
I would like to make some recommendations to improve the quality of work and
the health of the workers as well as to save time because I saw during my visit that the
machinery and equipment used there are old and the workers are over-diagnosed. It
takes time and effort to diagnose the problems. Modern machinery should be installed
and modern equipment should be used to increase efficiency and save time. This will
motivate the workers to perform their tasks more efficiently.
Safety measures need to be implemented i.e. wearing safety gloves, safety shoes
and goggles.
There is no need to fully expose the grinding machine as it can cause serious
hazards.
References
https://en.wikipedia.org/wiki/Pakistan_Railways#:~:text=History,-
Main%20article%3A%20History&text=In%201855%2C%20during%20the%20British,
Delhi%20Railway%20and%20Indus%20Flotilla.
https://www.abc-engines.com/
https://www.slideshare.net/MuhammadUsman1146/internship-at-pakistan-railways
https://sogema-engineering.com/en/assembly-2/
https://railcop.com.pk/ourservices/railway/
https://railcop.com.pk/construction/
https://www.brainkart.com/article/Railway--Preventive-Maintenance-of-
Locomotives_4329/
https://www.railwayage.com/news/does-rebuilding-locomotives-beat-buying-new/
https://pk.linkedin.com/in/nabeelejaz
https://resumecat.com/skills/generator-technician
https://www.bearing-news.com/easy-removal-bearings-wheels-drive-components/
https://www.stage8.com/railroad-locking-fasteners/railroad-cap-screw-locking-system-
for-roller-bearing-end-caps/
https://gemstatediesel.com/when-to-have-your-diesel-engine-overhauled/
https://www.admesy.com/articles/how-does-a-spectrometer-
work/#:~:text=A%20spectrometer%20is%20a%20scientific,section%20of%20the%20el
ectromagnetic%20spectrum.&text=For%20a%20spectrometer%20to%20operate,a%20n
umber%20of%20different%20components.