Professional Documents
Culture Documents
Roll NO : 19au027
1
Abstract
I have very good experience in Railway workshop. There are many types of work are
doing in the railway workshop. During the training I have coverd different shops like
Foundry shop, Tool shop, Power plant shop, Heat treatment shop,E&dc shop, Diesel
rehibition shop, Roller bearing shop, Diesel classified repair shop, Central Laboratory,
Power plant shop, Motor shop
In these shops I was different work experiences like material testing in Spectrometry
machine, Wheel Installation process, hardness and tensile making in furnace etc.
2
Acknowledgement
This Report has been prepared of the Industrial Training that has been done in the
Pakistan Railway Workshop to study the practical aspect of the course and
implementation of the theory in the field with the purpose of fulfilling the requirements
of the degree of BSc. Automotive Engineering Technology. I would like to express
my sincere gratitude to my teacher assistant professor Mr. Muhammad Shafi, ATC
Mr. Muhammad Ashraf in MET PR, all Forman, Charge man, and other staff
members who helped me for their support and encouragement.
Secondly I would also like to thanks my parents and friends who helped me a lot in
finishing this report within the limited time.
I am making this report not only for marks but to also increase my knowledge.
3
Table of Contents
Abstract .................................................................................................................................... 2
Acknowledgement ................................................................................................................... 3
Ch no 1 ..................................................................................................................................... 7
Introduction ......................................................................................................................... 7
Background .......................................................................................................................... 8
Hierarchy or Organogram .......................................................................................... 12
Chapter no 2 .......................................................................................................................... 13
Training Schedule ............................................................................................................... 13
Duties in different shop ..................................................................................................... 13
Ch. no 3 Work Experience ...................................................................................................... 23
4
Project no. 3: How to make the C&W Bearing in foundry shop .................................... 44
Project 4: Pins Heat treatment process: ........................................................................ 45
Supervisory Work ............................................................................................................... 47
Hand on Skills acquired ...................................................................................................... 47
How to improve productivity in Organization ................................................................... 47
Quality Management system in railway: ........................................................................... 48
Problem encounter and Problem solving .......................................................................... 49
Safety at work: ................................................................................................................... 50
Chapter no 5 .......................................................................................................................... 52
Conclusion: ......................................................................................................................... 52
Recommendation:.............................................................................................................. 52
CH 6 References ..................................................................................................................... 53
Appendix ................................................................................................................................ 54
5
Table of Figure
Figure 1 Pakistan Railway......................................................................................................... 7
Figure 2 Organogram ............................................................................................................. 12
Figure 3 Central Laboratory ................................................................................................... 14
Figure 4 Power plant .............................................................................................................. 15
Figure 5 Motor shop .............................................................................................................. 16
Figure 6 Heat treatment shop................................................................................................ 17
Figure 7Roller bearing shop ................................................................................................... 18
Figure 8 locomotive engine.................................................................................................... 19
Figure 9 E&DC shop................................................................................................................ 20
Figure 10 Tool shop ................................................................................................................ 21
Figure 11 Foundry shop ......................................................................................................... 22
Figure 12 UV - Spectrometry Machine................................................................................... 43
Figure 13 Mold making .......................................................................................................... 45
Figure 14 Furnaces ................................................................................................................. 45
Figure 15 Pins ......................................................................................................................... 46
6
Ch no 1
Introduction
The history of Pakistan Railways dates back to the British colonial era. The first
railway line was laid in 1858 between Karachi and Kotri, and since then, the network
has expanded to cover most of the country.
Certainly! Pakistan Railways is the national railway of Pakistan and operates both
passenger and freight services. It is the country's largest transportation organization,
with over 7,000 kilometers of track and 450 stations. The railway system is divided
into eight divisions, each with its own headquarters.
7
Background
Pakistan Railways was founded in 1861 during the British Raj. It is one of the oldest
railway systems in South Asia.
Pakistan Railways has been undergoing a major transformation in recent years. The
government has invested billions of dollars to upgrade the system, including the
purchase of new locomotives, passenger coaches, and freight wagons. The railway is
also working to modernize its signaling and communication systems. These
improvements are expected to make the railway safer, more reliable, and more
efficient.
The Pakistan Railway workshop are located in Mughalpura Lahore. This workshop are
established in 1908.The area of this railway workshop is 198Acres.This workshop
consist of 3 Departments. The name of the departments is given below:
8
The carriage and wagon shop is the department of Railway workshop. In
this carriage and wagon shop we are repairing the Boogies of train, Ac,
Power Busses, also making the parts of bogies etc.
There are following shops in this Carriage Shops below as:
Spring shop
Black Smith Shop
Power Plant Shop
Bearing Shop
Tool Shop
Heat Treatment Shop
Motor Shop
Wheel Shop
2. Loco Shop:
In this Departments repairing the engines of train, Inspection, Fault
Diagnosing, and engine overhauling etc.
There are following shops in this Loco Shops below as:
E&DC Shop
Tool Shop
Foundry Shop
Diesel Classified Repair Shop
Rehibition Shop
Black Smith Shop
Engine Block Shop
3. Central Laboratory
2-Chemical testing
2-Chemical testing:
9
In chemical testing two methods to perform chemical testing 1st is Spectrometry
Machine and 2nd is Wet conventional method. These methods are also performed in
ASTM.This is a National Organization is a Part of ISO (International Standard
Organization).
In this method different types of elements has been testing like zinc (Zn) Carbon (C)
etc. The Wet Conventional Method are performed in two ways 1st is Combustion and
2nd is Titation. In which testing a Lab person checking which quantity of carbon, iron
etc. are available in the piece of metal as per as Specification. In which each person
have to test performed each element it means 4 persons has to perform as per as 4
element. This process has to perform with different gadgets like Test tube, Flask,
Burner, Chemical etc. Each element has different temperature to testing. So this testing
method is very time consuming because 4 tests give the result after 4 days.
Spectrometry Machine
This is an Iron based machine. In which all types of iron based material pieces has
been checked like Aluminum (Au),Copper(C), Nickel (Ni),Zinc (zn),Lead (pb) etc. as
per as Specification. This machine has to Reducing the working as well as time
duration. This machine are connected to the Computer. This computer have to
checking 1 elements in a few Seconds.
The Physical Mechanical testing are testing in different methods like 1st is
Tensile/Yield and 2nd is Hardness.
1-Tensile/Yield:
In this method the pull the piece of metal and checking the breaking point. For the
checking of breaking point of piece of metal the UTM 9Universal Tensile Testing
Machine) has been used.
2-Hardness:
10
In Hardness a method is used to checking the hardness of a piece of metal through
Brinell Steel Ball (HB). In which machine drilling in the piece of metal like a hole.
The metal give the resistance against drilling. So that hole help to checking the
hardness of a piece of metal
11
Hierarchy or Organogram
WM
Skilled
Workers
Worker
Figure 2 Organogram
12
Chapter no 2
Training Schedule:
Sample Collect
Chemical Testing
13
Material Testing
Fuel Testing
Liquid Testing
Electrical Testing
Mechanical Testing
Power Buses Repairing
14
Figure 4 Power plant
15
Figure 5 Motor shop
16
Figure 6 Heat treatment shop
17
Figure 7Roller bearing shop
Engine overhauling
Engine Repairing
Parts Installation
Engine Installation
18
Figure 8 locomotive engine
19
Figure 9 E&DC shop
Bridge Reamers
Taps
Twist Drills
Ruling Cutters
Milano Cutters
20
Figure 10 Tool shop
Melting Material
Making Dies
21
Figure 11 Foundry shop
22
Ch. no 3 Work Experience
Daily Entry
23
Training Week: 2nd
Daily Entry
24
Training Week: 3rd
Daily
Entry
I learn sign of diesel engine may be weak and
need to be overhaul or need to be change
25
Training Week: 4th
Daily Entry
Today I learn about the safety factor use in heat
treatment shop
26
Training Week: 5th
Daily Entry
Today I learn how to done normalizing process for
decrease the internal stress develop after the cold
working process
Today I learn how to do hardening process for the
steel and matel toughness
27
Training Week: 6th
Daily Entry
Eid al-Fitr Holiday
28
Training Week: 7th
Daily Entry
Introduction with team of locomotive diesel shop
29
Training Week: 8th
Daily Entry
Today I learn how to inspect cylinder head valve
and valve guide
30
Training Week: 9th
Daily Entry
Today I learn how to inspect ring and piston and
play between the connecting rod and main journal
noises.
31
32
Training Week: 10th
Daily Entry
Today I learn about the fault diagnose of
lubrication system and check the the all leakages
and seepages in system
33
th
Training Week: 11
Daily Entry
I learn about the cooling system of locomotive
34
Training Week: 12th
Daily Entry
Today i learn inspection of wheel assembly
.
I learn how check bearing play in wheel assembly
35
Training Week: 13th
Daily Entry
36
Training Week: 14th
Daily Entry
I learn how to check work piece after completing the
work
37
Training Week: 15th
Daily Entry
Introduction with the team of E&DC Shop
38
Training Week: 16th
Daily Entry
Introduction with the foundry shop team and I learn
what are the safety factor in foundry shop
39
Training Week: 17th
Daily Entry
40
41
Ch. No 4 Project Carried Out
Projects
Project 1: How to Do the Spectrometer Analysis
42
Figure 12 UV - Spectrometry Machine
c. If I change ZCU 30 so first of all I have to titan the axle box spring with
chaises
In both locomotives I have disassembled the pull rod from wheel to body
After that disassembling the pull rod chaises of bogie is totally free from wheels
and traction motors
Left out the traction motor
Dismantle the gear box
Dismantle the axle box, axle bearing, axle housing etc.
After above all procedures are done the all parts are disassembled from wheel
43
Now I check all the parts if they are in working good condition or not
Now I have to install new wheel
After changing the wheel now I have to assembled all these parts
There are following procedures are to making the C&W bearing in foundry shop:
Firstly I have to check the bearing pattern to helping the making of bearing
Making the core or mold according to bearing pattern
After making the core I have to get the material for using to make the bearing
like Copper85%, Tin6%, Zinc5%, Lead5%, PH.CU0.1%
Getting all these material with correct ratio
Now putting above all material in the furnace
After putting the total materials in the furnace. Now ON the furnace
Now I will getting temperature in furnace at 1050c
When the temperature of furnace are reached to 105c. Now the material are in
melting position
After that we have Off the furnace
Now I have to getting the helping Tool for picking the melting material from
furnace
I also getting the core or mold that I have making before all that procedures
After this I have to get all the melting material with helping Tool and putting
into the core
After putting that material into the core
I will wait and watch until the material will be in cold or solid position
If the material in cold or solid position now I have to put out the bearing into
the core
Now the bearing is ready
44
Figure 13 Mold making
Figure 14 Furnaces
45
Putting the pins into the furnace
After putting into the furnace then turn ON the furnace
Heat the pins at 800 to 850c Temperature of furnace
When the temperature of furnace reach at 800 to 850c then putt out the pins
from the furnace
Now after the putting out the pins from furnace then I have to soaking the pins
into the water from 30 to 40 minutes
The pins are soaking into the water and the temperature of water is 27 to 43c
After soaking the pins at specific temperature the pins are again put into the
furnace
Now the temperature of the furnace is 400 to 425c
Again repeat the soaking process in 30 to 40 minutes
Now the pins are soaking in the normal air
Figure 15 Pins
46
Supervisory Work
Proactive Employee
Identify the and aligns goals and performance
Good working condition
Good Tools and equipment’s to making raise the productivity
47
Good relation with employees
Giving facility to employees
Making good environment in workstation
Be careful with safety precautions
Strength communication protocols
Give the right people to right task
Encourage learning opportunities
When the any part of locomotive engine or body are damaged so they are change
or replace the new part. Pakistan is considered on the sixth number in most populated
countries around the globe. Due to the high population, there’s an increase in the
demand for traveling of people in Pakistan.
Railways are considered the cheapest and most environmentally friendly mode of
transportation. It helps to transport the bulk of goods from one place to another over
long distances without any significant impact upon the environment. Rail is also one
48
of the transportation modes which is emission efficient and there are electric trains that
are powered by renewable energy.
1. Engine Overheat
Cause.
Remedies.
Cause.
Cause.
49
Remedies.
Causes.
Remedies.
Repair the fault of engine cooling system like thermostat valve, lack of
coolant etc.
Repair the fault of lubrication system like oil transmission pump, lack of
oil etc.
Repair the fault of cooling system like excessive amount of fuel are going
in the cylinder
Safety at work:
50
Don’t use your hands for stopping the machine
Whistling during the Overhead crane and shunting
51
Chapter no 5
Conclusion:
This training focused upon increasing our knowledge and interest in toward the
Production of Railway Carriage & Wagons and workshops. Because It is most efficient
and necessary needs to peoples in these days so its production at most efficient method
with minimum cost and in proper sequence with less wastage. It was a great
experience. It increases my practical skills that are the main thing which i learnt in the
training session. Thus, I believe that my training session will be beneficial for various
purposes & hence our efforts will be fruitful. Finally I would like to thank my
instructor and all the person of this organization who had helped me lot during my
course
Recommendation:
Making good management
Use latest machinery
Make clean environment
Apply rules and regulations with every person or employee
52
CH 6 References
1. Christian Wolmar, Blood, iron, and gold: How the railroads transformed the
world (Public Affairs, 2011).
53
Appendix
54