DEPARTMENT OF MECHANICAL TECHNOLOGY

Locomotive Railway
Works
AHMED ALVI
2013-UET-KIT-MECH-24
ENGR.IRFAN KHATAK
Contact +92 322 6857041 email;ahmedalvi3@gmail.com

DEPARTMENT OF MECHANICAL TECHNOLOGY

Abstract
This report describes the work conducted during the internship at the
mughalpura railway works. This internship is part of the degree.The
main purpose of my internship report is to clear the concept and try to
explain Railway works.
I learned about how locomotives and their parts work.
I came to know different types of locomotives.
I learned and inspect all the workshops process.

DEPARTMENT OF MECHANICAL TECHNOLOGY

 Aims & Objectives
The objectives of internship are to interconnect my theoretical
knowledge to the practical field and understand the parameters of
Railway workshops work and their operations and to know about
railway engine etc.
The main objective of this internship is to understand locomotive train
engine .
To study on workshops operations.
To understand industrial production.
The aim of the internship is to study the production process.

DEPARTMENT OF MECHANICAL TECHNOLOGY

Schedule of internship
Sr.No Name of shops Period of training
1 Diesel classified shop 26/1/17 to 3/2/17

2 Foundry shop 4/2/17 to 15/2/17

3 E & DC shop 16/2/17 to 28/2/17

4 Spring shop 01/3/17 to 10/3/17

DEPARTMENT OF MECHANICAL TECHNOLOGY

 Literature Review
History
The Moghalpura Railway Workshops are one of several Pakistan
Railways rolling stock repair sites, located on the LahoreWagah Branch
Line at Moghalpura Junction railway station in Lahore, Pakistan. The
workshop complex began to emerge at its present site in 1904 in order
to manufacture, repair and overhaul passenger coaches and freight
wagons for the then North Western State Railway. After Pakistan's
independence in 1947, it was the only state-of-the-art workshop for
Pakistan Railways

DEPARTMENT OF MECHANICAL TECHNOLOGY

 Department During
Internship
The departmnts and sections where I spend my time and inspect are
following:
Locomotive department
Foundry department
Electric and diesel shop
Spring department

DEPARTMENT OF MECHANICAL TECHNOLOGY

Workshops in mughalpura
locomotive works
Diesel classified and rehabilitation shop
Power assembly shop
High capacity wagon shop
Machine shop
Foundry shop
E&DC shop
Spring shop
Wheel shop
Machine maintinence shop

DEPARTMENT OF MECHANICAL TECHNOLOGY

ORGANIZATIONAL
STRUCTURE:

DEPARTMENT OF MECHANICAL TECHNOLOGY

Diesel classified shop
The responsibility of diesel classified work shop is overhauling of all
locomotives of Pakistan Railways after every 5 years. In diesel classified
shop there are different section that perform preventive maintenance
of different parts.

DEPARTMENT OF MECHANICAL TECHNOLOGY

DIESEL LOCOMOTIVE
A diesel locomotive is a type of railway locomotive in which the prime
mover is a diesel engine. Several types of diesel locomotive have been
developed, differing mainly in the means by which mechanical power is
conveyed to the driving wheels.

DEPARTMENT OF MECHANICAL TECHNOLOGY

TYPES OF LOCOMOTIVES
s.no Name of locomotive Code Manufacuerd by
number
01 Hitachi bambordian universal HBU-20 America

02 General motor canedian universal GMCU-15 Caneda

03 Diallanpakistan universal DPU-30 China

04 Zialliancoaporation universal ZCU-30 China

05 American locomotive universal ALU-95 America

06 Re-engineering general electric GRE-20 Caneda

07 Green tiger AG-30 America

DEPARTMENT OF MECHANICAL TECHNOLOGY

SECTIONS OF DIESEL
CLASSIFIED
There are following sections of diesel classified shop. Each section
performs its
respective operation.
1. Power Assembly Section
2. Electric Section
3. Crank Shaft Section
4. Radiator Section
5. Nozzle Section
6. Engine Governor Section

DEPARTMENT OF MECHANICAL TECHNOLOGY

Schedule of maintenance
Each of these locomotives having different class of power from 1500HP
to 3000HP, but now pakistanrailway added a new class of loco having
power upto 4000 HP known as (GE-40) Perchased from America. Most
of these locomotives are four stroke diesel engine and GMCU-15 is only
a two stroke diesel engine.
Minimum period Duration

After every trip For six hours

After one month For eight hours

After three month For one day

After six month For three days

After one year For one week

DEPARTMENT OF MECHANICAL TECHNOLOGY

Types of Diesel Engine
Diesel engine is divided into two types
Vertical engine
V-type engine
Vertical engine
In this types the engine is fitted in verticledirection.each connecting rod
is clamp with a separate journal.these engines are
ALCO-95 6 cylinder four stroke
ALCO-12 6 cylinder four stroke
HAU-10 6 cylinder four stroke

DEPARTMENT OF MECHANICAL TECHNOLOGY

Types of Diesel Engine
V-type engine
The cylinder of these engines are mounting on a same journal like v
shape at a angle of 45digree.
Fllowing engines are v-type engine
AG-30
GMU-30
ALU-24
ZCU-30

DEPARTMENT OF MECHANICAL TECHNOLOGY

Parts of diesel engine
Diesel engine is consist on following parts:
crank case
cylinder block
crank case motor
crank shaft
connecting rod
main bearing
piston and piston rings
cam shaft

DEPARTMENT OF MECHANICAL TECHNOLOGY

Parts of diesel engine

DEPARTMENT OF MECHANICAL TECHNOLOGY

 Foundry Shop
In foundry shop different types of parts are produced using casting
process. After casting the work pieces are machined to convert them
into various parts according to part structure. Various types of furnaces
are available in at Loco shop of railway industry to cast different
number of parts accordin g to demand.
.

DEPARTMENT OF MECHANICAL TECHNOLOGY

TYPES OF FURNACES
There are different types of furnaces available in foundry shop. The
furnaces are as follow:
Cupola Furnace
Tilt Furnace
Rotary furnace

DEPARTMENT OF MECHANICAL TECHNOLOGY

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

DEPARTMENT OF MECHANICAL TECHNOLOGY

 Tilting Furnace:
A tilt furnace is also a melting device used in foundries that can be used
to melt aluminum and some bronzes. It is called tilts furnace because
molten metal can be get by tilting the furnace. The cupola can be made
almost any practical size.. 550-600faluminum
Brass melting temp=1050-1150f

DEPARTMENT OF MECHANICAL TECHNOLOGY

Rotary furnace:
Rotary Melting Furnace is very flexible & universal equipment used
forrecycling many non-ferrous metals. Rotary Furnace is a batch type
process furnace. It is designed according to capacity. In Rotary Furnace
the required quantity of raw material is filled along with a
proportionate charge of additives. It is used to melt raw iron.

DEPARTMENT OF MECHANICAL TECHNOLOGY

PARTS MADE IN FOUNDRY
SHOP

DEPARTMENT OF MECHANICAL TECHNOLOGY

PARTS MADE IN BRASS
FOUNDRY
There are following parts are prepared in this shop:
Sliding door handle
Upper birth handle
Coat hook
Window catcher
Window stopper
Window panel
Glass stand
Motor cover

DEPARTMENT OF MECHANICAL TECHNOLOGY

PARTS MADE IN IRON
FOUNDRY
There are following parts are prepared in this shop:
L.P cylinder for D.E loco
H.P cylinder for D.E loco
Oil tank cock body
Disc brake
Brake shoes
Caps for alternator body
Brake block
Plug for oil tank cock body

DEPARTMENT OF MECHANICAL TECHNOLOGY

E &DC SHOP
In this shop all parts related to diesel engine are preared and machined
here:
Parts prepared and machined here are:
oil seal
friction plate
discharge valve
valve guide
planger lubricant
bearing shell

DEPARTMENT OF MECHANICAL TECHNOLOGY

Sections in E &DC SHOP
grinding section
milling section
lathe section

Machines used in E & DC SHOP

Hydraulic machines
Vertical milling machines
Bench lathes
Center lathes

DEPARTMENT OF MECHANICAL TECHNOLOGY

SPRING SHOP
in this shop all types of springs are prepared and manufactured here
Springs are flexible machine element used for controlled application of
force or torque or for storing and release of mechanical energy.

DEPARTMENT OF MECHANICAL TECHNOLOGY

Types of spring
The following types of springs are prepared here:
Buffer spring
Coil helical spring
Leaf spring

DEPARTMENT OF MECHANICAL TECHNOLOGY

SPRING MAKING PROCESS
There are following steps used in making of springs
1. Cutting
2. Heating of coil head
3. Heating in bar heating furnace
4. Coiling of spring
5. Spacing of coil
6. Hardening of coil
7. Tempring
8. Scrag test

DEPARTMENT OF MECHANICAL TECHNOLOGY

Spring making process
9. Load test
10. Finishing/grinding
11. painting

DEPARTMENT OF MECHANICAL TECHNOLOGY

1.cutting
In cutting the material is cutted in requried size:

DEPARTMENT OF MECHANICAL TECHNOLOGY

2.Heating of coil head
In this step head of coil is made in heating furnace:

DEPARTMENT OF MECHANICAL TECHNOLOGY

3.Heating of coil
In this step the coil is heated in bar heating furnace and the
tempreature is 860c to 900c.

DEPARTMENT OF MECHANICAL TECHNOLOGY

4.Coiling of spring
This process is done on double bar lathe machine after heting.

DEPARTMENT OF MECHANICAL TECHNOLOGY

Coiling of spring

DEPARTMENT OF MECHANICAL TECHNOLOGY

5.SPACING

DEPARTMENT OF MECHANICAL TECHNOLOGY

6.Hardening of coil spring
In this step the coil spring is diped into oil.

DEPARTMENT OF MECHANICAL TECHNOLOGY

7.Tempring
In this step the coil is tempred into the temper furnace.480-510c

DEPARTMENT OF MECHANICAL TECHNOLOGY

9.Grinding finishing

DEPARTMENT OF MECHANICAL TECHNOLOGY

Contact details of person(s)
incharges
Diesel classified shop:
Sikandar hayat (forman mechanical) diesel classified shop.
Muhammad nafees (charge man) 0300-4804758.
E &DC Shop:
Basharat rasheed (forman)
Foundry shop:
Muhammad imtiaz (Forman)
Spring shop:

DEPARTMENT OF MECHANICAL TECHNOLOGY

Future Recommendations for
junior Students
Pakistan railway is the best place to learn all mechanical work.this is the
house of mechanical workshops.

DEPARTMENT OF MECHANICAL TECHNOLOGY

References
"$8.2b railtrack upgrade project wins go-ahead - The Express
Tribune". The Express Tribune. 2016-06-08. Retrieved 2016-06-23.
Wikipedia: Narrow gauge
railwayhttp://www.pildat.org/publications/publication/GovernanceAss
essment/PerformanceAnalysisofPakistanRailways.pdf
Liszewski, Andrew (15 March 2017). "The Reason Trains Have Angled
Wheels Is Incredibly Clever". Gizmodo. Retrieved 14 March 2017.
http://www.pakrail.com/ybook2.pdf

DEPARTMENT OF MECHANICAL TECHNOLOGY

DEPARTMENT OF MECHANICAL TECHNOLOGY