A Final Internship Report Submitted to the Punjab Tianjin

University of Technology, Lahore In the Fulfillment of the

Requirements for the Degree of B.Sc. (Hons)

AUTOMOTIVE ENGINEERING TECHNOLOGY.

Industrial training organization: Pakistan Railway

Session (2019-2023)

Submitted by: Muhammad Tayyab Jamil

Reg. No: 19AU030

Industrial training course:

Industrial training period:27-03-2023 to 22-07-2023

1
UNDERTAKING

I certify that this internship report is my own work. No portion of the work presented
in this report has been submitted in support of another award or qualification either at
this institution or elsewhere. Where material has been used from other sources, it has
been properly acknowledged.

Muhammad Tayyab Jamil

19AU030

Supervisor: __________________

Principal: ___________________

2
ACKNOWLEDGEMENT

Firstly, I really want to thank to our creator for bestowing our

necessary courage, good health, and mental ability to manage
self- directed study and to complete it in a specific period of time.

Secondly, I would like to thank our parents and our family, who
encourage and impart believed in us that I do our best. They are
really very special entities in our life, without their continuous
support in all aspects of our life, I would never have the
opportunity to do this or the many other valuable experiences that
they made possible.

Third, thank to our professors for their valuable guidance, in every

stage of the study is greatly appreciated and I also wish to express
my gratitude to the officials and other members of Railway
Pakistan who rendered their help during the period of my training.

3
ABSTRACT

This internship report aims to provide an overview of the valuable experiences gained
during an internship in the railway sector. The report focuses on the intern's
involvement in projects aimed at enhancing railway infrastructure. The internship
offered hands-on experience in various aspects of railway development, maintenance,
and upgrading processes. The report details the intern's role within the organization,
including responsibilities, tasks, and achievements throughout the internship period. It
also highlights the application of theoretical knowledge acquired during academic
studies and its practical implementation in railway engineering projects.
Key areas covered in this report include:

1. Overview of the railway sector: An introduction to the railway industry, its

significance, and respective challenges faced in infrastructure development,
maintenance, and safety.

2. Internship duration and organization: An overview of the internship

duration, the organization where the intern was placed, and the specific
department and team they were assigned to.

3. Objectives and scope: A clear outline of the objectives and scope of the
internship, focusing on developing skills and knowledge related to railway
infrastructure enhancement.

4. Tasks and responsibilities: A detailed description of the tasks assigned to the

intern, ranging from assisting in surveying and data collection to contributing
to the design and implementation of infrastructure improvements.

Overall, this internship report serves as a comprehensive account of the intern's

engagement in enhancing railway infrastructure. It outlines the practical application of
theoretical knowledge, development of technical skills, and personal growth achieved
through the internship experience. The report aims to provide insights and
recommendations for future interns, as well as contribute valuable knowledge to the

field of railway engineering and infrastructure development.

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 TABLE OF CONTENT
Chapter 1

Backgrounds of Training Organization …………………………………09

Chapter 2

Schedule of Training & Duties, as Trainee………………………………13

Chapter 3

Training Log Book………………………………………………………15

Chapter 4

Working Experiences

3.1 Central Laboratory MGPR………….……………………………….32

3.2 Power Plant Shop C&W Shop………..…………………...................34

3.3 Heat Treatment Shop C&W Shop……………………………............36

3.4 Roller Baring Shop C&W Shop………………………………...........39

3.5 Diesel Classified Repairing Shop Loco………………………………43

3.6 Diesel Rehabilitation Shop Loco Shop…………...………...................52

3.7 Motor Shop C&W Shop…………….……………………...................56

3.8 E&DC Shop Loco Shop…………………………...……………...……58

3.9 Tool Shop Loco Shop………………………………………………….61

3.10 Foundry Shop Loco Shop …………………………………………....63

Project #1……………………………………………………………….….65

Project #2……………………………………………………………….….67

Project #3……………………………………………………………….….69

Chapter 5

Conclusions……………………………….………………………......73

Recommendations……………………………………………….........73

5
Chapter 6

References…………………………………………………………...74

6
 Table of Figures
Figure #1…………………………………………………………………………...09

1.1………………………………………………………………………………….09

Figure #2…………………………………………………………………………...32

2.1………………………………………………………………………………….33

2.2………………………………………………………………………………….33

2.3………………………………………………………………………………….34

2.4………………………………………………………………………………….35

Figure #3………………………………………………………………………….36.

3.1………………………………………………………………………………….36

3.2………………………………………………………………………………….36

3.3………………………………………………………………………………….37

Figure #4………………………………………………………………………….38

4.1………………………………………………………………………………….39

4.2………………………………………………………………………………….39

4.3………………………………………………………………………………….40

4.4………………………………………………………………………………….43

Figure #5……………………………………………………………………….......44

5.1………………………………………………………………………………….45

5.2…………………………………………………………………………………...46

5.3……………………………………………………………………………………47

5.4……………………………………………………………………………………49

Figure #6…………………………………………………………………………….54

6.1……………………………………………………………………………………55

6.2……………………………………………………………………………………56

6.3……………………………………………………………………………………56

6.4……………………………………………………………………………………56

7
Figure #7…………………………………………………………………………….57

7.1……………………………………………………………………………………57

7.2…………………………………………………………………………………....58

7.3……………………………………………………………………………………58

7.4……………………………………………………………………………………58

Figure #8…………………………………………………………………………….59

8.1……………………………………………………………………………………59

8.2……………………………………………………………………………………59

8.3……………………………………………………………………………………60

8.4……………………………………………………………………………………61

Figure #9…………………………………………………………………………….62

9.1……………………………………………………………………………………62

9.2……………………………………………………………………………………63

9.3……………………………………………………………………………………64

9.4……………………………………………………………………………………64

Figure #10…………………………………………………………………………...65

10.1………………………………………………………………………………….65

10.2…………………………………………………………………………………65

10.3…………………………………………………………………………………66

10.4………………………………………………………………………………….67

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INDUSTRIAL TRAINING SCHEDULE

SR.NO. NAME OF SHOPS PERIOD OF TRAINING

1 Central Laboratory MGPR 27-03-2023 to 30-03-2023

2 Power Plant Shop C&W Shop 31-03-2023 to 10-04-2023

3 Motor Shop C&W Shop 11-04-2023 to 30-04-2023

4 Heat Treatment Shop C&W Shop 01-05-2023 to 09-05-2023

5 Roller Baring Shop C&W Shop 10-05-2023 to 20-05-2023

6 Diesel Classified Repair Shop Loco 21-05-2023 to 10-06-2023

7 E&DC Shop Loco Shop 11-06-2023 to 17-06-2023

8 Tool Shop Loco Shop 18-06-2023 to 24-06-2023

9 Foundry Shop Loco Shop 25-06-2023 to 06-07-2023

10 Diesel Rehabilitation Shop Loco 07-07-2023 to 22-07-2023

Shop

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TRAINING WORKSHOPS

 Central Laboratory MGPR

 Power Plant Shop C&W Shop
 Motor Shop C&W Shop
 Heat Treatment Shop C&W Shop
 Roller Baring Shop C&W Shop
 Diesel Classified Repairing Shop Loco
 E&DC Shop Loco Shop
 Tool Shop Loco Shop
 Foundry Shop Loco Shop
 Diesel Rehabilitation Shop Loco Shop

10
CHAPTER # 1

Introduction

History and Background

Pakistan Railways is the national, state-owned railway company of

Pakistan Founded in 1861 head quartered in Lahore, it owns 4,800
miles (7,791 km) of track across Pakistan from Torkham to Karachi and
operates freight and passenger services. Pakistan Railways was also
known as the Pakistan Western Railway from 1947 to 1974.

In 2014 the Ministry of Railways launched Pakistan Railways Vision

2026, which seeks to increase the company's share of the transportation
sector from four to 20 percent with the ₨886.68 billion (US$8.4
billion) China–Pakistan Economic Corridor rail upgrade. The plan
includes new locomotives, development, and improvement of current
rail infrastructure, an increase in average train speed, improved on-time
performance, and expansion of passenger service. The first phase of the
project was completed in 2017, and the second phase is scheduled for
completion by 2021. Pakistan Railways is an active member of the
International Union of Railways. In the 2018/19 financial year,
Pakistan Railways carried 70 million passengers.

In 1855, during the British Raj, several railway companies began laying track 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
11
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 Seined,
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.

Following the partition of British India and independence of Pakistan 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.

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 converted to 1,676 mm (5 ft. 6 in) broad gauge. The Kot Adu–
Kashmore section of the Kotri–Attock Railway Line was built from 1969 to 1973,
providing an alternate route from Karachi to northern Pakistan. In 1974, Pakistan
Western Railways was renamed Pakistan Railways. In February 2006, the 126-
kilometre (78 mi) Hyderabad–Khokhrapar Branch Line was converted
to 1,676 mm (5 ft. 6 in). All narrow-gauge tracks in the country were converted
to 1,676 mm (5 ft. 6 in) or dismantled during the 2000s. On 8 January 2016,
the Lodhran–Raiwind Branch Line double-rail project was completed.

12
Manufacturing

Pakistan Locomotive Factory

The Pakistan Locomotive Factory was built in Risalpur in 1993 at a

cost of ₨228.4 million (US$2.2 million). The factory's capacity is
150 coaches per year on a single-shift basis.

Carriage Factory

The Carriage Factory Islamabad was built for manufacturing new

carriages for Pakistan Railways in 1970.

Mughalpura Railway Workshops

The Moghalpura Railway Workshops, on the Lahore–Wagah Branch

Line at Moghalpura Junction railway station (MGPR) in Lahore, are
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. After Pakistan's independence in 1947, it was the only state-
of-the-art workshop for Pakistan Railways.

Concrete Sleeper Factories

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.

13
CHAPTER # 2
SCHEDULE OF TRAINING & DUTIES AS TRAINEE:

SR.NO. NAME OF SHOPS PERIOD OF TRAINING

1 Central Laboratory MGPR 27-03-2023 to 30-03-2023

2 Power Plant Shop C&W Shop 31-03-2023 to 10-04-2023

3 Motor Shop C&W Shop 11-04-2023 to 30-04-2023

4 Heat Treatment Shop C&W Shop 01-05-2023 to 09-05-2023

5 Roller Bearing Shop C&W Shop 10-05-2023 to 20-05-2023

6 Diesel Classified Repair Shop Loco 21-05-2023 to 10-06-2023

7 E&DC Shop Loco Shop 11-06-2023 to 17-06-2023

8 Tool Shop Loco Shop 18-06-2023 to 24-06-2023

9 Foundry Shop Loco Shop 25-06-2023 to 06-07-2023

10 Diesel Rehabilitation Shop Loco 07-07-2023 to 22-07-2023

Shop

Duties as Trainee
So the whole period of training divided among the two mentioned workshops of
Railway. The period starts from 27-03-2023 to 22-07-2023. During this, I was
appointed as a trainee by MET in C&W Shops and in Loco Shop.

Following Shops are given below:

 Roller Bearing Shop (Carriage & Wagon Shop)

▪ Taper
▪ Cylindrical
 Motor Shop
▪ Petrol Engine
▪ Diesel Engine

 Heat Treatment Shop

14
 ▪ Hardening
▪ Tempering
▪ Normalizing
 Power Plant Shop
▪ Power Vans
 Diesel Classified Repair Shop & Rehabilitation Shop (Loco Shop)
▪ Engine Overhauled
▪ Engine Assembly
 Tool Shop
▪ Taper Turning
▪ Shaper
▪ Grinding

15
Chapter #3
INDUSTRIAL TRAINING LOG BOOK
Training Information

Personal Details

Student Name: Muhammad Tayyab Jamil

Student Roll: 19AU030

Address: VPO Fatehpur Tehsil & District Gujrat

Email: tayyabjamil114@gmail.com

Course of Study: Automotive Engineering Technology

Year/Semester of Study: 8th

Training Start Date: March 27th, 2023.

Training End Date: July 22nd, 2023

Training Organization

Name: Pakistan Railway

Address: MET Center

Mughalpura, Lahore.

16
 Daily Training Log
Training Week: 1st

Daily Entry
It’s my first day at MET College introduction with
teachers.

Today I have attend the class about the history of Pakistan

Railway and introduction of existing workshops in
Pakistan Railway

Today my 1st day in Power Plant shop (C&W) and

introduction with staff.

Today I learn about the basic system operation use in power

plant shop

I learn how to work Diesel generator

Today I learn identification of diesel generator parts and
how many brands use in Pakistan Railway

Declaration:

I hereby declare that all information provided above is true.

Signed by Trainee Signed by Supervisor

17
 Daily Training Log

Training Week: 2nd

Daily Entry

Today I learn about the control systems of generators

use in Pakistan railway

Today I learn about the circuit breaker control panel and

their specifications

Today I learn safety factor use in motor shop and how to

work in motor shop
Today I learn basic difference in diesel and petrol engines

Today I learn how to check engine oil radiator

coolant and also know how check the vehicle
through visual inspection.
Today I learn how to disassemble diesel engine for
engine overhauling.

Declaration:

I hereby declare that all information provided above is true.

Signed by Trainee Signed by Supervisor

18
 Daily Training Log

Training Week: 3rd

Daily Entry

I learn sign of diesel engine may be weak and need

to be overhaul or need to be change

Today I learn sign of petrol engine maybe weak and need

to be overhaul or need to be replace.

Today I learn how to piston ring adjustment in

diesel engine

Today I learn how to adjustment of timing of diesel

engine during overhauling.

Today I learn method of petrol engine overhauling and

how to adjust ignition timing during engine overhauling

Today I learn how to inspect engine after

overhauling.

Declaration:

I hereby declare that all information provided above is true.

Signed by Trainee Signed by Supervisor

19
 Daily Training Log

Training Week: 4th

Daily Entry
Today I learn about the safety factor use in heat
treatment shop

Today I learn how to work in heat treatment shop and

know what are the operation perform in heat treatment
shop
Today I learn about how to increase resistance in metal
Today I learn how to mechanical and electrical
properties of metal and how to increase the
machinability properties increase
I learn how to done annealing process for the softening
of metal , steel and copper and learn what are the basic
temperature use for this process.

Declaration:

I hereby declare that all information provided above is true.

Signed by Trainee Signed by Supervisor

20
 Daily Training Log
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 metal toughness

Today I learn how to do tempering and nit riding process

in metal

Declaration:

I hereby declare that all information provided above is true.

Signed by Trainee Signed by Supervisor

21
 Daily Training Log

Training Week: 6th

Daily Entry

Today I learn how to do cyaniding and carburizing

process
Today I learn purpose of these process in metal and steel

I learn about the types of furnaces and which material

use for making these furnaces

Identification of parts of the locomotive engines use in

Pakistan railway
Today I learn introduction of locomotive shop and
which kind of shops in locomotive block

Declaration:

I hereby declare that all information provided above is true.

Signed by Trainee Signed by Supervisor

22
 Daily Training Log

Training Week: 7th

Daily Entry
Introduction with team of locomotive diesel shop

Today I learn about the basic specification of engines use

in Pakistan railway
I identify the sensor use in locomotive engine

Identification of parts of the locomotive engines use in

Pakistan railway
I learn about electrical system and their working

I learn about 6 month engine inspection checking point

Today I learn about diesel injection pump and its

working

Declaration:

I hereby declare that all information provided above is true.

Signed by Trainee Signed by Supervisor

23
 Daily Training Log

Training Week: 8th

Daily Entry
Today I learn how to inspect cylinder head valve
and valve guide

Today I learn how to check water jackets and elbows

through visual inspection and then through different
types of test
Today I learn how to check oil level oil and oil condition
in locomotive CAT & Pillar engines

Today I how to dismantle locomotive engine for the

overhauling

Today I learn how to inspect engine internal parts after

dismantling the locomotive engine

Today I learn how to check crankshaft and camshaft

inspection method

Declaration:

I hereby declare that all information provided above is true.

Signed by Trainee Signed by Supervisor

24
 Daily Training Log

Training Week: 9th

Daily Entry
Today I learn how to inspect ring and piston and
play between the connecting rod and main journal

Today I learn how to fix the any king of seepage

on engine. I learn the seepage fixing of oil sump.

Today I learn about the diagnosing and fixing of
We Diagnose the engine oil comes from Engine
Timing Side (Engine front Side). We replaced the
Oil seal to fix it.
Today I fix or re assemble the engine with
complete overhauling and check the any kind of
leakage and seepage

Today I learn about how to check all basic systems

after the engine overhauling

Today I get an overview of engine

Troubleshooting
Engine misfire with abnormal internal lower

noises.

Declaration:

I hereby declare that all information provided above is true.

Signed by Trainee Signed by Supervisor

25
 Daily Training Log

Training Week: 10th

Daily Entry
Today I learn about the fault diagnose of
lubrication system and check the all leakages and
seepages in system

Today I learn about the compression testing of

new assemble engine during the final inspection
of engine

I learn how to get an dry and wet compression test

Today I learn turbocharger function in locomotive

engine

I learn how to work of turbocharger in locomotive

engines

I learn how to diagnose the fault of turbocharger in

locomotive .

Declaration:

I hereby declare that all information provided above is true.

Signed by Trainee Signed by Supervisor

26
 Daily Training Log

Training Week: 11th

Daily Entry
I learn about the cooling system of locomotive

Today I learn about the main fault of cooling system

and how to fix them

I learn how to replace water pump in locomotive

engines
I learn how to check thermostat valve and water
jackets

I learn how to work diesel lift pump in locomotive

Today I learn flywheel inspection of locomotive

engines

Declaration:

I hereby declare that all information provided above is true.

Signed by Trainee Signed by Supervisor

27
 Daily Training Log

Training Week: 12th

Daily Entry
Today i learn inspection of wheel assembly

.
I learn how check bearing play in wheel assembly

I learn how to dismantle the wheel bearing from

wheel assembly
I learn how to load test on a bearing

I learn how to refit bearing in wheel assembly

I learn how to check bearing after refitting on wheel

Declaration:

I hereby declare that all information provided above is true.

Signed by Trainee Signed by Supervisor

28
 Daily Training Log

Training Week: 13th

Daily Entry

Introduction with the staff of Tool shop

I learn parts identification of Lathe Machine

I learn how to make an clutch and flywheel hosing

and what are the basic operation use in clutch
housing

I learn how to do facing process

I learn how to drilling and honing process

I learn how turning and knurling process

Declaration:

I hereby declare that all information provided above is true.

Signed by Trainee Signed by Supervisor

29
 Daily Training Log

Training Week: 14th

Daily Entry
I learn how to check work piece after completing the
work

I learn how to do operation on specific angles

I learn how working a pneumatic tools

I learn how to cutting the tool on shaper machine

How to inspect the tool after completing the process

Declaration:

I hereby declare that all information provided above is true.

Signed by Trainee Signed by Supervisor

30
 Daily Training Log

Training Week: 15th

Daily Entry
Introduction with the team of E&DC Shop

Here I learn purpose of friction plate and how to

make it
I learn how to make an oil seal valve guide and
plunger .

I learn how to make bearing shell connecting rod

I learn how to face a crankshaft of Perkins and

Cummins engine

Today I learn how to check dimension of crankshaft

after facing

Declaration:

I hereby declare that all information provided above is true.

Signed by Trainee Signed by Supervisor

31
 Daily Training Log

Training Week: 16th

Daily Entry
Introduction with the foundry shop team and I learn
what are the safety factor in foundry shop

I learn how to make a mold and what type of

material use for making the mold and also know
how to inspect a mold after completing this
Today I learn how to melt a iron for
molding
Today I learn ow to check a brake system in train

I learn how to test vacuum and pressure brake

system during the half year inspection

I learn how to check traction motor and learn

how its work

Declaration:

I hereby declare that all information provided above is true.

Signed by Trainee Signed by Supervisor

32
 Daily Training Log

Training Week: 17th

Daily Entry
I learn how to dismantle traction motor and how
to change their starter.
I learn how to refit the traction motor and inspect
again for final inspection
I learn how to check overhaul bogie inspection
I learn how to inspect bogie suspension system
and how to check shock absorber
I learn how to inspect fuel tank and Ac system
during the inspection

Declaration:

I hereby declare that all information provided above is true.

Signed by Trainee Signed by Supervisor

33
CHAPTER# 4
WORKING EXPERIENCE
In this chapter, we’ll discuss the major learning outcomes through this training and
will see some important components and equipment installed in various sites and shops
of Pakistan Railways workshops. In all workshops, there are multi-functional and
many types of fabrication, manufacturing, processing and some special purpose
machines used. We know all machine operated by some sort of energy. Electrical
energy is very suitable to control, convert and some other purposes. So we used
electrical machine and equipment in all our fabrication, processing and some other
purpose machines. Therefore, I learned about some useful equipment installed in the
various workshops. The detailed description of some useful components and
equipment installed in workshops are given in coming sections of this chapter.

Project Carried Out

In these 16 weeks of training session, I’ve got some projects by industrial training
supervisor. According to my training schedule, my duties are to go through dedicated
working sites or workshops and get knowledge about working nature and equipment
used in these workshops and get myself familiar with the usage of multiple equipment
and machines used in these workshops. I’ve completed some workshops listed below
with details about work and some useful equipment that are used in these workshops
and sites. The following subsections describe the workshop detail and some briefly
description of my work that I’ve done at these workshops.

Central Laboratory MGPR

There are two types of testing are performed in the Central laboratory

1-Physical mechanical testing

2-Chemical testing

These testing are explained below.

34
Chemical testing
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).

Wet Conventional Method

In this method different types of elements have been testing like zinc (Zn) Carbon (C)
etc. The Wet Conventional Method are performed in two ways 1st is Combustion and
2nd is Titration. 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
has to test performed each element it means 4 persons has to perform as per as 4
elements. 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.

Fig. 1.1 (Wet Conventional Method)

35
 Fig.1.2 (Chemical Laboratory)

Spectrometry Machine

This is an Iron based machine. In which all types of iron-based material pieces have
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 is connected to the computer. This computer has to checking 1
element in a few Seconds.

Physical Mechanical Testing

The Physical Mechanical testing are testing in different methods like 1st is
Tensile/Yield and 2nd is Hardness. These methods are explaining below.

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

In Hardness a method is used to checking the hardness of a piece of metal through

Briella Steel Ball (HB). In which machine drilling in the piece of metal like a hole.
The metal gives the resistance against drilling. So that hole helps to checking the
hardness of a piece of metal.

36
Working Experience

The central laboratory in Pakistan Railways is responsible for conducting various tests
and analyses related to the railway operations and maintenance. These laboratories are
equipped with modern equipment and facilities to carry out testing and quality control
of materials used in railway tracks, bridges, signaling systems, rolling stock
components, and other infrastructure elements.

It's essential to note that the working experience and scope of a central laboratory in
Pakistan Railways may vary depending on its location, resources, and the specific
priorities of the railway management.

Fig.1.3 (Hardness and Tensile Methods)

37
Power Plant Shop C&W Shop
In Power plant shop we are working on the Power Van. You can say it’s a movable
power house. This shop working on the generation of electricity. In this shop all
Pakistani trains are overall, repair as per as diagnosis. In this shop the power van is
coming in the end of the year to overall. But sometime the train Diagnosis issue like
Electrical or Mechanical issue they have coming within the year. In electrical issues
like power van, fuel tank etc. The trains are issue in Electrical is call NRE (Nominated
Repair Electrical). In Mechanical issues like suspension, axle, tire, body etc. The trains
are issue in Mechanical is called NRM (Nominated Repair Mechanical). The small
power vans is called TL (Train Lighting van). According to design there are different
types of design are installed in train like (20 30 45 100 300 350 500) kva. The function
of locomotive is to start the engine. The function of power van is to provide electricity
to ON the train accessories like (Lights, Fans, Air Condition) etc.

Kva depends on horse power according to engine. In which trains different companies
of engines are installed like Perkins (England), Cummins and cater pillar (Americans)
are use in the train. Perkins’s engines (20kv) were used only to light up lights and turn
on fans. While Cummins, Caterpillars (300-450) Kwa these were used to run AC and
also fans etc.

Fig.2.1 (Power Plant Shop)

38
According to the arrangement of cylinders, an engine is
classified are primarily into following categories:

 In Line
 ‘I’ Shaped
 ‘V’ Shaped
 ‘W’ Shaped
 Flat/Horizontally Opposed

In Line Engine:
This type of design is a very basic and conventional engine design. In this engine
construction, the cylinders are in a single straight line. An inline engine is used with
2, 3, 4 or up to 8 cylinders.

Fig.2.2 (In Line Engine)

V Engine:
This is a newer generation engine design. In this engine construction, the cylinders are
at an angle. The angle between the cylinders forms a 'V' shape and that is
why it is a 'V' engine design.

39
 Fig.2.3 (V Engine)
W Engine:
In this engine construction, the engine has three rows of cylinders placed at an angle.
The angle between the cylinder rows forms a 'W' shape and that is why it is a 'W'
engine design.
Engine Parts

 Engine Block
 Crankshaft
 Cylinder head
 Piston
 Connecting rod
 Cylinder liner
 Inlet and exhaust valve
 Flywheel
 Engine timing gear
 Intake and exhaust air manifolds
 Turbocharger
 Thermostat
 Fuel injection pump
 Lube oil cooler (for diesel)
 Radiator and radiator fan
 Lube oil circulation pump
 Water circulation pump
 Self-starter

40
  Camshaft
 Fuel filter, lube oil filter, air cleaner
 Rocker arm
 Head gasket

Fig.2.4 (Power Plant Shop)

41
 Fig.2.5 (Control Board)





 Fig.2.7 (Power Van)

42
 Fig.2.7 (Control Board)

Working Experience
The power plant shop in Pakistan Railways is responsible for maintaining and
repairing locomotives and other rolling stock to ensure smooth operations on the rail
network. The shop may handle various types of engines, such as diesel-electric
locomotives, electric locomotives, or steam locomotives, depending on the technology
used in different sections of the railway.

It's important to note that the working experience in any organization can evolve over
time, influenced by factors such as technological advancements, organizational
changes, and government policies.

43
Heat Treatment Shop C&W Shop

Heat treatment is defined as an operation involving the heating and cooling of a

metal or an alloy in the solid-state to obtain certain desirable properties without
change composition. The process of heat treatment is carried out to change the grain
size, to modify the structure of the material 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, brine or molten salts. The heat treatment process includes
annealing, case hardening, tempering, normalizing and quenching, nit riding,
cyaniding etc. Heat Treatment Process Flow Chart Shown in figure.

Fig.3.1 (Heat Treatment)

44
Types of Heat Treatment Processes

Eight different types of heat treatment processes are as follows:

1. Annealing
2. Normalizing
3. hardening
4. Tempering
5. Nit riding
6. Cyaniding

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
softening process. 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 Fig.3.2 (Annealing)
malleable and to remove internal stresses.
This process makes the steel soft so that it can be easily 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 temperature and
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 Fig.3.3 (Normalizing)
45
normal condition.
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
process of annealing.

Fig.3.4 (Hardening)

Tempering
Tempering: When the hardening process
hardness a steel specimen, it becomes
brittle and has high 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 Fig.3.5 (Tempering)
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.

46
Nit riding
Nit riding 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 and Flame hardening objects are
heated by an oxy-acetylene flame.

Purpose of Nit riding: Fig.3.6 (Nit riding)

 To harden the surface of the steel to a certain depth.

 Increase resistance to wear and fatigue.
 To increase corrosion resistance.

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.

Working Experience
It is worth noting that Pakistan Railways is a large organization that operates a vast
network of railways, and heat treatment may be used in various aspects of their
operations, including maintenance and repair of railway tracks and components.

47
Roller Bearing Shop C&W Shop
Roller bearings also known as rolling-element bearings are similar
to ball bearings in that they are designed to carry a load while
minimizing friction. However, roller bearings transmit loads using
cylinder rolling elements, rather than balls, to maintain the
separation between moving parts of the bearing. These versatile
bearings can contain single or multiple rows of rolling elements;
multiple rows can significantly improve radial load capacity. Also,
the use of different roller shapes can further reduce friction and
support both radial and axial loads. While roller bearings can handle
higher loads than conventional ball bearings, theirapplications 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, and multiple bearing rowscan allow
for higher performance to meet specific application needs.

Roller Bearing Types and Application

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 radialloads and are able to be used in high-
speed applications.

48
 Fig.4.1 (Cylindrical Roller Bearing)

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 internal clearances and retainer options, spherical roller
bearings can handle axial loading in either directionas well as heavy
shock loads. These bearings are available in bore dimensions ranging
from 20 mm to 900 mm. This type of bearing is shown in fig.

Fig.4.2 (Spherical Roller Bearing)

49
 Needle roller bearings
This type of bearing is thinner than conventional roller bearings and
can be designedwith 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.

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 available in inch and metric sizes. Roller
bearings are used in a wide range of applications, from
heavy equipment and machinery to power generation,
manufacturing, and aerospace.

Working Experience

The working experience of any shop, including roller bearing shops in Pakistan
Railways, may vary depending on factors such as the shop's location, size,
management, and the skills and dedication of the employees. Generally, a roller
bearing shop in Pakistan Railways would be responsible for maintaining, repairing,
and supplying roller bearings used in railway equipment and machinery.

50
Diesel Classified Repair & Rehabilitation Shop Loco

In Diesel Classified Shop Engines are being overhauled are and

equipped with new accessories If needed. Locomotive of are overhauled
after a period of 5 Years.

Diesel Classified Shop Has Following 5 Sections:

 Power assembly section

 Nozzle, fuel injection, & pump section
 Air compressor
 Electrical section
 Engine section

The Diesel Locomotive

The modern diesel locomotive is a self-contained version of the electric locomotive.

Like the electric locomotive, it has electric drive, in the form of traction motors driving
the axles and controlled with electronic controls. It also has many of the same auxiliary
systems for cooling, lighting, heating, braking and hotel power (if required) for the
train. It can operate over the same routes (usually) and can be operated by the
same drivers. It differs principally in that it carries its own generating station around
with it, instead of being connected to a remote generating station through overhead
wires or a third rail. The generating station consists of a large diesel engine coupled to
an alternator producing the necessary electricity. A fuel tank is also essential. It is

51
interesting to note that the modern diesel locomotive produces about 35% of the power
of a electric locomotive of similar weight.

Fig.5.1 (Diesel Engine)

Diesel Engine

This is the main power source for the locomotive. It comprises a large cylinder block,
with the cylinders arranged in a straight line or in a V. The engine rotates thedrive shaft
at up to 1,000 rpm and this drives the various items needed to power the locomotive.
As the transmission is normally electric, the engine is used as the power source for the
alternator that produces the electrical energy to drive the locomotive.

 Main Alternator
 Auxiliary Alternator
 Motor Blower
 Air Intakes
 Rectifiers/Inverters
 Electronic Controls
 Control Stand
 Cab
 Batteries

52
  Traction Motor
 Pinion/Gear
 Fuel Tank
 Air Reservoirs
 Air Compressor
 Drive Shaft
 Gear Box
 Radiator and Radiator Fan
 Sand Box
 Mechanical Transmission
 Fluid Coupling
 Gearbox
 Final Drive
 Hydraulic Transmission
 Wheel Slip

Working Experience
Pakistan Railways has a fleet of diesel locomotives that are used to haul trains on
various routes throughout the country. Diesel locomotives require regular maintenance
and repair to ensure their optimal performance and reliability. This maintenance work
includes routine servicing, overhauling, and rehabilitation of locomotives that have
undergone significant wear and tear. Please note that the specifics of working
experiences can vary depending on the individual's position, the specific role in the
diesel repair and rehabilitation process, and the policies and practices of Pakistan
Railways at any given time.

53
Motor Shop C&W 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

 Petrol section.
 Diesel section.

Automobile vehicles owned by Pakistan Railway are being fixed and

overhauled at the petrol division. 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 expelled out 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 to ignite 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 increase high enough if it was heavily
54
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 vehicles having higher compression ratios of up to 13.

Working Experience
Working in a motor shop of Pakistan Railways typically involves maintenance, repair,
and overhaul of locomotives, railcars, and other railway vehicles. The motor shop is
responsible for keeping the railway fleet in good working condition to ensure safe and
efficient operations. The work environment in a motor shop can be challenging, as it
involves working with heavy machinery and sometimes under tight deadlines to keep
the railway fleet operational. Safety protocols are crucial in this setting to prevent
accidents and injuries. It's important to note that experiences can vary depending on
the specific location, size of the motor shop, and individual job responsibilities.

55
E & DC Shop Loco Shop
It is a section in Locomotive shop in which different machining processes are executed to
make several mechanical parts Locomotives of Pakistan currently in operation and owned by
Pakistan Railways consist of diesel locomotives. Steam locomotives are no longer used in
Pakistan.Pakistan Railways has 29 electric locomotives of class BCU30Enumbered 7001-
29. These are British-built locomotives of 3,000horsepower for 25 kV AC. They are stored out
of use because the overhead lines are unserviceable, owing to theft of copper.

An electro-diesel locomotive is a type of locomotive that can be powered either from

an electricity supply (like an electric locomotive) or by using the onboard diesel engine
(like a diesel-electric locomotive). Machining of electrical and diesel components done
in this shop.

Following Locomotive components are being manufactured and repaired in this shop.
There are three main sections in this shop where above mentioned locomotive
components are manufactured.

 Lathe Section
 Milling Section
 Grinding and boring Section

Machines used in E & DC SHOP:

 Hydraulic machines
 Vertical milling machines
 Bench lathes
 Center lathes
 Universal grinding machines
 Universal milling machines

Parts prepared and machined here are:

 Bearing shell
 Con rod Fig.6.1 (Tools Board)
 Con rod bush
 Rotter shaft
 All types of bushes
 Crank shaft of compressor
56
  Oil seal
 Friction plate
 Discharge valve
 Valve guide
 Plunger lubricant

Sections in E &DC SHOP

 Grinding section
 Milling section
 Lathe section
 Turbo rotor assembly section
 Fitting section

Fig.6.2 (Grinding Section)

57
 Fig.6.3 (Milling Section)

Working Experience

The working experience in the E&DC Shop in Pakistan Railways typically involves a
team of skilled technicians, engineers, and mechanics who are well-versed in the
electrical and diesel systems of locomotives. It's important to note that the working
experience may vary depending on the specific location, size of the E&DC Shop, and
the overall state of Pakistan Railways' infrastructure and resources.

58
Tool Shop Loco Shop

A machine shop is a room, building, or company where machining is

done, which is a form of subtractive manufacturing. In a machine shop,
machinists use machine tools and cutting tools to make parts, usually
of metal or plastic (but sometimes of other materials such as glass or
wood).

Machines

A machine is a tool containing one or more parts that uses energy to

perform an intended action. Machines are usually powered by
mechanical, chemical, thermal, or electrical means, and are often
motorized. Historically, a power tool also required moving parts to
classify as a machine.

However, the advent of electronics has led to the development of power

tools without moving parts that are considered machines

Machining

Machining is any of various processes in which a piece of raw material

is cut into a desired final shape and size by a controlled material-
removal process. The many processes that have this common theme,
controlled material removal, are today collectively known as
subtractive manufacturing, in distinction from processes of controlled
material addition, which are known as additive manufacturing. Exactly
what the "controlled" part of the definition implies can vary, but it
almost always implies the use of machine tools (in addition to just
power tools and hand tools).

59
Machine tools

A machine tool is a machine for shaping or machining metal or other

rigid materials, usually by cutting, boring, grinding, shearing, or other
forms of deformation. Machine tools employ some sort oftool that does
the cutting or shaping. All machine tools have some means of
constraining the work piece and provide a guided movement of the
parts of the machine. Thus the relative movement between the work
piece and the cutting tool is controlled or constrained by the machine
to at least some extent, rather than being entirely "offhand" or
"freehand".

Examples of machine tools are:

 Broaching machine
 Drill press
 Gear shaper
 Hibbing machine
 Hone
 Lathe
 Screw machines
 Milling machine
 Shear (sheet metal)
 Shaper
 Saws
 Planer
 Stewart platform mills
 Grinding machines
 Multitasking machines (MTMs)—CNC machine tools
with many axes that combine turning, milling, grinding,
and material handling into one highly automated machine
tool

60
  When fabricating or shaping parts, several techniques are used
to remove unwanted metal. Amongthese are:
 Electrical discharge machining
 Grinding (abrasive cutting)
 Multiple edge cutting tools
 Single edge cutting tools

Broaching
Broaching is a machining process that uses a toothed tool, called a broach, to remove
material. A broaching processed Material shown in figure no-05.

Drill press
A drill is a tool primarily used for making round holes or driving fasteners. It is fitted
with a bit, either a drill or driver, depending on application, secured by a chuck. Some
powered drills also include a hammer function.
Gear shaper
A gear shaper is a machine tool for cutting the teeth of internal or external gears. The
name shaper relates to the fact that the cutter engages the part on the forward stroke
and pulls awayfrom the part on the return stroke, just like the clapper box on a planer
shaper. A gear shaper machine and schematic figure of gears shown in fig.
Milling
Milling is the process of machining using rotary cutters to remove
material by advancing a cutter into a work piece. This may be done
varying direction on one or several axes, cutter head speed, and
pressure. Milling covers a wide variety of different operations and
machines, on scales from small individual parts to large, heavy-duty
gang milling operations. A simple Vertical Milling Machine Shown. It
is one of the most commonly used processes for machining custom
parts to precise tolerances.

Shaper
A shaper is a type of machine tool that uses linear relative motion between the work
piece and a single-point cutting tool to machine a linear tool path. Its cut is analogous
to that of a lathe, except that it is (archetypally) linear instead of helical. A vertical
shaper machine shown in fig.

61
Grinding
Grinding is an abrasive machining process that uses a grinding wheel as the cutting
tool. Grinding Process of the material is shown in figure-12. A wide variety of
machines are used for grinding:
 Hand-cranked knife-sharpening stones (grindstones)
 Handheld power tools such as angle grinders and die grinders
 Various kinds of expensive industrial machine tools called grinding
machines
 Bench grinders

Working Experience
However, in general, a tool shop in Pakistan Railways would be responsible for
providing and maintaining various tools and equipment used in the maintenance and
repair of railway infrastructure and rolling stock. This may include tools for repairing
tracks, locomotives, wagons, and other railway assets.Working in a tool shop in
Pakistan Railways, like any job, would involve various tasks such as inventory
management, tool maintenance, handling tool requests from different departments, and
ensuring that all tools are in good working condition. The environment may be fast-
paced and require collaboration with other railway staff to ensure the smooth
functioning of the railway operations.

62
Foundry Shop Loco Shop:

A foundry is a factory that produces metal castings. Metals are cast

into shapes by melting them into a liquid, pouring the metal into a
mold, and removing the mold material after the metal has solidified as
it cools. The most common metals processed are aluminum and cast
iron. However, other metals, such as bronze, brass, steel, magnesium,
and zinc, are also used to produce castings in foundries. In this process,
parts of desired shapes and sizes can be formed.

In metalworking, casting involves pouring liquid metal into a mold,

which contains a hollow cavity of the desired shape, and then allowing
it to cool and solidify. The solidified part is also known as a casting,
which is ejected or broken out of the mold to complete the process.
Casting is most often used for making complex shapes that would be
difficult or uneconomical to make by other methods.

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 part structure. Various types of furnaces are

available in at Loco shop of railway industry to cast different

number of parts according to demand. Operations to be performed and

time to make that part are mentioned on work order. Operations

are performed according to the sequence mentioned on work order.

Furnaces:

 Cupola furnace
 Rotary furnace

63
Casting products:

 Gear
 Vacuum brake
 Diesel brake

Fig.10.1 (Gear)

Parts prepared in brass foundry:

There are following parts are prepared in this shop

 Sliding door handle

 Upper birth handle

Working Experience
A foundry shop in Pakistan Railways or any other organization involved in metal
casting would typically be responsible for producing various metal components, such
as train parts, using the casting process. The casting process involves melting metals
and pouring the molten metal into molds to create the desired shapes.

It's essential to note that specific working experiences can vary based on the particular
foundry's size, capabilities, location, and management practices.

64
Project #1

Diesel Electric Locomotives Rehabilitation

Evaluation
The importance of the railways in Pakistan’s national policy has been maintained in
the 8th 5-year Plan and the current Ten Year Perspective Plan, and the Medium Term
Development Framework (MTDF) prepared in 2005. In the 8th 5-year Plan, the
government desired in particular, to raise the railway/road freight transport ratio from
14:86 in 1990 to 20:80 in 1997, because the freight and passenger transport was overly
biased toward road. Meanwhile, the aging of locomotives in the Pakistan Railways
became a critical issue,5 and the Pakistani government allotted approximately 31% of
public investment in the transportation sector budget to the railway sector, with the
stated goal of maintaining and improving transportation capacity through repair and
procurement of locomotives and improvement of other aspects of operation. The
project was consistent with this policy, and its importance was high. In the current Ten
Year Perspective Plan, particular emphasis is placed on expansion of the share of long-
distance railway freight transport.

Among the 20 investment project plans in the railway sector, 8 projects are for
rehabilitation, manufacture, or new purchase of locomotives and are allotted
approximately 48% of the transportation sector budget. Thus, the project continues to
maintain its relevance. In Medium Term Development Framework, development of
transportation infrastructure including railways is stated as a key issue.6 As of April
2007, Pakistan Railways possesses 531 locomotives, and 63% of those have exceeded
their durable life. The locomotives rehabilitated by this project and in Phase 1 (totaling
102) constitute 52% of the locomotives that have not exceeded their durable life, and
the project is contributing to measures against overaged locomotives. Moreover, for
low-income passengers who use railways as their primary means of transport, the
importance of the project is high.

65
Project Cost
The planned project cost totaled 9.849 billion yen, while the actual project cost was
9.168 billion yen, or 93% of the planned cost. During the period of delay, costs
increased by approximately 1.5 times on local currency basis due to inflation, but on a
yen basis, this increase was absorbed by fluctuation in the exchange rate.

Diesel Locomotive Rehabilitation

66
Project #2
Diesel Electric Locomotives Production Project

Evaluation
In this project, a total of 54 locomotives were rehabilitated and 30 locomotives with
3,000-horse power were manufactured almost as planned. The project period was
substantially exceeded the plan due to a local currency shortage and delay in parts
manufacturing, but the project cost rose slightly over the plan. Immediately after the
rehabilitated locomotives were put into service (1998), their rate of operation and
operational efficiency significantly exceeded the average level of the

Pakistan Railway. However, 2 years after the rehabilitation, some of the locomotives
required parts replacements, and in 2003, they were operating at nearly average levels.
The 30 newly manufactured locomotives perform the best of all the railway’s diesel
electric locomotives and are used for passenger transport. Overall, superannuation of
the locomotives of the Pakistan Railway is advancing; however, the 84 locomotives
rehabilitated and manufactured by this project constitute 16% of the locomotive fleet
and are contributing to the maintenance of transportation capacity. These locomotives
also bear 41% of the passenger transport load and 17% of the freight transport load,
with approximately 30 million persons per year (approx. equivalent to the Keihin
Kyuko Hamedan Line in Japan) using trains pulled by these locomotives. There are no
problems in the technical capacity of the Pakistan Railway, and with regard to the
operation and maintenance system,

reforms are progressing, including formation of a public corporation and consignment

of operations to private companies. Financially, the Pakistan Railway is in deficit, but
it is increasing income by raising fares and boosting the number of high-speed trains.
The lessons learned from this project are to set an appropriate scope for the project
with sufficient consideration of future increases in operation and maintenance
expenses.

67
Third Party Evaluator’s Opinion
To utilize the advantage of railway transport, such as environmental aspect, over road
transport and to further boost the effects of the project, it is necessary for the Pakistan
Railways to conduct reforms with an emphasis on human resources development.

Diesel Locomotive Plant

68
Project #3

Wheel Maintenance
Designing a project for wheel maintenance in the Pakistan railway industry requires
careful planning and consideration of various factors. Below is an outline for such a
project:

Project Overview:
Clearly define the purpose and scope of the project. The primary objective is to
enhance the efficiency and safety of the Pakistan railway system by improving wheel
maintenance practices.

Research and Data Collection:

Conduct a comprehensive study of the existing wheel maintenance practices in
Pakistan's railway industry. Gather data on the frequency of wheel failures,
maintenance procedures, and associated costs. Identify the key challenges faced in
maintaining railway wheels.

Needs Assessment:
Analyze the data collected to determine the specific needs and requirements for an
effective wheel maintenance program. Identify areas that need improvement and
prioritize them based on their impact on safety and operational efficiency.

Infrastructure and Technology Upgrade:

Assess the current infrastructure and technology used in wheel maintenance. Consider
upgrading or acquiring modern equipment, tools, and technologies to improve the
accuracy and efficiency of maintenance processes.

Training and Skill Development:

Develop training programs for railway maintenance personnel to ensure they are well-
versed in the latest maintenance techniques and safety protocols. This may involve
collaborations with specialized training institutes.

69
Establishing Maintenance Facilities:
Set up dedicated wheel maintenance facilities strategically located along the railway
network. These facilities should be equipped with the necessary machinery and
resources to handle wheel inspections, repairs, and replacements.

Preventive Maintenance Schedule:

Implement a preventive maintenance schedule to proactively inspect and maintain
wheels at regular intervals. This approach can help identify and address potential
issues before they escalate into more significant problems.

Quality Assurance and Standards:

Define and adhere to strict quality assurance measures and industry standards for
wheel maintenance. This will ensure uniformity and consistency in maintenance
practices across different locations.

Data Analytics and Predictive Maintenance:

Incorporate data analytics and predictive maintenance techniques to monitor the
condition of wheels continuously. This can help predict maintenance needs accurately
and reduce unscheduled downtimes.

Collaboration with International Experts:

Collaborate with international railway maintenance experts and organizations to learn
from their best practices and experiences. This can foster knowledge transfer and help
the Pakistan railway industry adopt global standards.

Monitoring and Evaluation:

Set up a monitoring and evaluation system to track the progress and effectiveness of
the wheel maintenance project. Regularly review the project's outcomes and make
necessary adjustments to improve performance.

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Public Awareness and Safety Campaigns:
Conduct public awareness campaigns to educate passengers and stakeholders about
the importance of wheel maintenance in ensuring safe and reliable railway operations.

Financial Planning and Funding:

Develop a detailed financial plan outlining the estimated costs of the project and
potential funding sources. This may involve seeking government support, public-
private partnerships, or international funding.

Implementation Timeline:
Create a realistic timeline for the project's implementation, including milestones and
deadlines for key activities.

Reporting and Documentation:

Maintain detailed documentation of the project, including progress reports,
expenditures, and lessons learned, to aid future endeavors and share knowledge with
other railway industries. By following this comprehensive project outline, the Pakistan
railway industry can significantly improve its wheel maintenance practices, leading to
enhanced safety, reduced operational costs, and increased customer satisfaction.

Wheel Maintenance

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Chapter #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’s 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.

RECOMMENDATIONS:
I would like to give some recommendations to improve the quality of work and save
time along the health of the workers because during our visit we observed that the
workers are not playing with their own lives which are a great loss of man power.

Motivation comes for any work, from within and heavily depends on individual
consideration, which are bound to be different for each human positiveness of
character makes him/her flexible, tolerant and sound in any specific consideration. The
positiveness heavily depends on the individual’s education and curiosity. During my
course of training in pakistan Railway Workshop. I have experienced an immense
pleasure \while comparing the text that I have come across practically conversing with
people and obtain through questionnaire Pakistan railway workshop mughalpura
Lahore is the best place where you can learn many things about related to mechanical
works. This is the Asia’s largest mechanical workshop here you can see all operations
and mechanical practical’s. Training methods, techniques and equipment continue to
be upgraded to the latest standards. Trainees are taken on extensive study tours over
the PR network to acquire practical knowledge

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Chapter #6

References
http://pu.edu.pk/images/journal/studies/

http://www.railways.gov.pk/

https://themechanicalengineering.com/

https://learnmechanical.com/

https://www.pakrail.gov.pk/images/pmu/mech_code_wkps.pdf http://www.railcop-
pk.com/introduction.htm https://en.wikipedia.org/wiki/Pakistan_Railways

https://www.thenews.com.pk/print/434106-a-visit-to-the-workshop-that-keeps-
pakistan-railways-locomotives-chugging

https://www.researchgate.net/publication/262011817_History_of_Pakistan_Rail
way

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 Training Certificate

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