INTERNSHIP REPORT

Muhammad Ali
BS Mechanical Engineering

NOVEMBER 24, 2014

PAKISTAN RAILWAYS
M.E.T Center Mughalpura

Contents
1

Introduction: ............................................................................................................................ 2

Abstract: .................................................................................................................................. 2

Workshops: ............................................................................................................................. 2
3.1

Locomotive Workshops: .................................................................................................. 2

3.1.1

Diesel Classified: ...................................................................................................... 2

3.1.2

Air Brake Section:..................................................................................................... 4

3.1.3

Engine Block Shop: .................................................................................................. 5

3.1.4

Machine Shop: .......................................................................................................... 5

3.1.5

Mill Shop: ................................................................................................................. 5

3.2

Carriage Workshop: ......................................................................................................... 5

3.2.1

Power Van Shop: ...................................................................................................... 5

3.2.2

Spring Shop:.............................................................................................................. 6

3.2.3

Steel Fabrication Shop: ............................................................................................. 6

1 Introduction:
For an engineer Pakistan Railways is one of the best organization for exposure in a practical way.
It covers moreover all the engineering disciplines. As railway repairing and maintenance
workshops covers the mechanical discipline of engineering so I have done a month internship in
different sections of these workshops. Unfortunately due to poor bureaucratically held decisions
and lack of concern from the higher officials these workshops have not been administered and
functioned properly.

2 Abstract:
During my internship I have visited different sections of the locomotive and carriage workshops
and see how different components of the train are repaired and maintained. Moreover I have also
saw overhauling of different engine parts i.e. turbo charger, pump and nozzle, radiator,
compressor, engine block and governor during my internship.

3 Workshops:
During my internship I have visited the two workshops:
1. Locomotive Workshop.
2. Carriage Workshops.

3.1 Locomotive Workshops:

In this workshops all the components related to the locomotive of the trains are overhauled,
repaired and maintained. Following shops have been visited during my internship:
3.1.1 Diesel Classified:
In this shop complete overhauling and repairing of the engine section of the locomotive is done.
This shop is divided into the following sections:
3.1.1.1 Engine Section:
In this section complete overhauling of the engine has been done. The main things that I learned
are briefly described as follows:

Two types of engines have been used I Type and V Type, both are overhauled after 3 and
6 years respectively. The I type engine consists of 6 cylinders and V type engine consists
of 12 cylinders.

The engine first dismantled and the components are sent to their respective sections.

The I type engine is overhauled in 20-25 days and V type engine is overhauled in 25-30
days.

In this section all the fitting of the engine has been done which enables me to see all the
parts and components of the engine.

The main components of the engine i.e. pistons, connecting rods and crankshafts are
cleaned by different and polished by using different tools.

The crankshafts surface cracks is checked by using a Magna Flux and then passing a
current through the shaft.

The bearings are cleaned and changed.

One of the main drawback is that the staff uses manual tools in order to get the required
torque values for nuts and bolts which can be possible on smaller nuts put in bigger
assemblies higher torque values are required which cant be attained by human power. So
in order to get these values levers are used and 4-5 men are used to tighten one nut which
is quite dangerous and time consuming and most importantly less accurate.

There are no health, safety and environment legislation in the workshop i.e. the workers
are working in sandals and sleepers without any gloves and helmets thats why the
probability of an injury is very high in this shop.

3.1.1.2 Turbo Section:

Turbo charger is used to suck the air into the system and as well as to exhaust the residual gasses
out of the system. Since it operates dual functions so it increases the engine efficiency.

All the components of the turbo charger are assembled and repaired in this shop.

Machining of different parts of the turbo charger are done in this shop.

After the assembly turbo charger is tested on the test bed.

As mentioned earlier there is no proper health, safety and environment legislation in this
shop.

3.1.1.3 Truck Section:

Truck is the part of the engine which moves the i.e. wheels and traction motors are placed on this
structure.

Complete structural analysis of the truck is done in this section.

Different fixtures and jigs are made as a standard in order to check if there is variation in
the dimensions of the components.

3.1.1.4 Head Section:

In this section the engine head is maintained and overhauled.

Exhaust and intake valves are checked and their surfaces are polished after washing.

Rocker assemblies are also checked.

3.1.1.5 Nozzle & Pump Section:

Nozzle is used to inject the fuel into the cylinder and pump is used to pump the fuel from the fuel
tank to the nozzle.

Complete overhauling of nozzle and pump is done in this section.

Different test are performed in order to check the desired characteristics of the pump and
nozzle.

3.1.1.6 Governor Section:

Governor is used to control the fuel supply to the engine and it is also used to control the speed of
the engine.

Complete overhauling of governor is done in this section.

Different tests are performed in order to check the desired features of the governor.

3.1.2 Air Brake Section:

The locomotives used in Pakistan railways are equipped with air brake systems.

All the components i.e. pipes and valves in this system are checked and repaired in this
sections.

Different test are performed in order to check the desired characteristics of the air brake
system.

3.1.3 Engine Block Shop:

In this shop engine block which contains engine components is washed and cleaned at desired
temperatures using different cleaning medium.
3.1.4 Machine Shop:
In this shop shaping different components of locomotive is machined by using different techniques
i.e. lapping, hubbing, facing and honing.
3.1.5 Mill Shop:
In this shop milling of the different components of the locomotive is done by using different
machinery.

3.2 Carriage Workshop:

In this shop carriage vans of the trains are repaired overhauled and maintained. I have visited the
following shops in this workshop.
3.2.1 Power Van Shop:
In this shop power vans of the different trains are overhauled, repaired and maintained.

The power generated in the trains for electricity and air conditioning are generated by these
power vans.

The power is generated by different engines of specific powers coupled with compatible
generators.

Different type of engines are used according to the load of the train.

All type of engines and generators that are used in the trains are overhauled in this shop.

One of the main drawback is that the staff uses manual tools in order to get the required
torque values for nuts and bolts which can be possible on smaller nuts put in bigger
assemblies higher torque values are required which cant be attained by human power. So
in order to get these values levers are used and 4-5 men are used to tighten one nut which
is quite dangerous and time consuming and most importantly less accurate.

The engines are tested on artificial created water load.

3.2.2 Spring Shop:

Different springs that are used in the carriage vans are completely manufactured in this shop.

The spring rod is heated at a specific temperature in the furnace.

Then this rod is rolled.

Then it is cooled under specific conditions.

The spring surface is checked by passing a current and magnetizing it and then watching
its surface in the UV light.

3.2.3 Steel Fabrication Shop:

In this shop steel sheets of different gauges are manufactured and fabricated here. These sheets are
cut according to the sizes by cutters.