Internship Report Pakistan Railway Workshops

Acknowledgements

I would like to thank all our teachers and supervisors of each departments guiding us in
understanding the concepts of related Basic Mechanical Technology in Industry
(Workshops). So his cooperation and support to bring this task to completion. I would also
like to thank my families and friends for their continuous encouragement and moral support.

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Executive Summary

The main purpose of this internship report is to fulfill the partial requirement of the degree of
BS Mechanical Engineering and to become familiar with the practical working conditions of
business-organization. Pakistan Railway has the sole rights to conduct the operation of rail in
whole country. It provides lot of facilities to the people of different field in shape of carrying
passengers and transport of goods from all around the country. Pakistan Railway is one of the
largest organization of the country. It also plays a vital role in reducing the unemployment
rate in the country. Pakistan Railway is also providing many facilities to business community,
not only within country but also across the border like rail link with India.

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Table of Content

Carriage & Wagon Shops P.R Mughalpura

Sr. No. Section Objective

1 Section I.1 Industrial Introduction of the Pakistan Railway

2 Section I.2 Introduction of the Tool Shop CC. 7115

3 Section I.3 Introduction of the Machine Shop CC.7124

4 Section I.4 Introduction of the Wheel Shop CC.7124

5 Section I.5 Introduction of the Lifting Shop CC. 7120

(Bearing Section)
6 Section I.6 Introduction of the Spring Shop CC. 7101

7 Section I.7 Introduction of the Black Smith Shop CC. 7113

8 Section I.8 Introduction of the Air Condition Shop CC. 7308

9 Section I.9 Introduction of the Power Plant Shop CC. 7551

Locomotive Workshops
10 Section I.10 Introduction of the Machine Shop CC. 7005

11 Section I.11 Introduction of the Foundry Shop CC. 7001

Conclusion
Future Recommendations about Pakistan Railway Workshops

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Overview of the Organization

Section I.1

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Objective
Industrial Introduction of Pakistan Railway.

1.1 Pakistan Railway History

2.1 Importance of Pakistan Railway
3.1 Railway Board
4.1 Functional Units
5.1 Divisions
6.1 Classes
7.1 Organizational Structure
1.1 Pakistan Railway History

Pakistan Railways formerly also known as the Pakistan WesternRailway between 1947 and 1
974, is the national state-owned railwaycompany of  Pakistan. Founded in 1861 and
headquartered in Lahore, it owns 7,400 miles (11,881 km) of track across Pakistan, stretching
from Torkham to Karachi and operates both freight and passenger train services.

In 2014, the Ministry of Railways launched "Pakistan Railways Vision 2025".

₨886.68 billion (US$8.5 billion) China Pakistan Economic Corridor railway upgrade, seeks
to reinvigorate Pakistan Railways by increasing its share in the transportation sector from 4%
to 20% by 2025. The plans include the acquisition of new locomotives, developing and
improving current rail infrastructure, increasing average train speeds, improving punctuality
and expanding passenger services. The first phase of the project will be completed in
December 2017, while the second phase will be completed by 2021 Pakistan Railways in an
active member of the International Union of Railways.

Rail transport in Pakistan began in 1855 during the British Raj, when several railway
companies began laying track and operating in present-day Pakistan. The country's rail
system has been nationalized as Pakistan Railways (originally the Pakistan Western
Railway). The system was originally a patchwork of local rail lines operated by small private
companies, including the Scinde, Punjab and Delhi Railways and the Indus Steam Flotilla. In
1870, the four companies were amalgamated as the Scinde, Punjab & Delhi Railway. Several
other rail lines were built shortly thereafter, including the Sind–Sagar and Trans–Baluchistan
Railways and the Sind–Pishin, Indus Valley, Punjab Northern and Kandahar State Railways.
These six companies and the Scinde, Punjab & Delhi Railway merged to form the North
Western State Railway in 1880. Following independence in 1947, the North Western Railway
became Pakistan Western Railway and the rail system was reorganized; some of the

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reorganization was controversial. Rail use increased in early 1948, and the network became
profitable. Declining passenger numbers and financial losses in the late 1980s and early
1990s prompted the closure of many branch lines and small stations. The 1990s saw
corporate mismanagement and severe cuts in rail subsidies. Due to falling passenger
numbers, government subsidies are necessary to keep the railways financially viable.

Figure 1 Pakistan Railway

2.1 Importance of Pakistan Railway

Pakistan railway provides an important mode of transportation throughout Pakistan. It

plays an important role in bringing the farthest corners of the country closer for the
purpose of business, sightseeing, education, pilgrimage and many other important
services.

Railways were the most important infrastructure development in India from 1850 to 1947.
In terms of the economy, railways played a major role in integrating markets and
increasing trade. In terms of politics, railways shaped the finances of the colonial
government and the Princely States.

Railways stretches its hands in conducting activities like business, sightseeing, and
pilgrimage along with transportation of goods. It is easier for long-distance travel. Plays a
vital role in national integration. It strengthens the development of the industry and
agriculture.

3.1 Railway Board

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The Railway Board functioned from 1959 to 2000 and was modified with addition of the
"Executive Committee of Railway Board" between 2000 and 2014. However, the Railway
Board was reconstituted again on February 20, 2015. The Minister of Railways Secretary
serves as the official chairman of the Pakistan Railway Board.

The autonomous board consists of:

 Secretary (Minister of Railways)

 Secretary, Communications Division
 Secretary, Finance Division
 Secretary, Planning & Development Division
 General Manager (Operations)
 General Manager (Manufacturing & Services)
 Member Finance, Ministry of Railways. This composition could not get parliament
approval and presently the Board consists of ex-officio member listed above with
three members from private sector, appointed by Govt. The Secretary Railways is also
Chairman of the Board. The secretariat of Board is headed by Secretary Railway
Board. The seat of Board is Ministry of Railways, Islamabad.
4.1 Functional units

Pakistan Railways comprises three functional units:

 Operations
 Manufacturing
 Welfare & special initiative unit
5.1 Divisions

Pakistan Railway comprises seven territorial operating divisions:

 Karachi
 Lahore
 Multan
 Peshawar
 Quetta
 Rawalpindi
 Sukkur
6.1 Classes

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Pakistan Railways has several classes of travel. Depending on the route, certain trains may
only have a single class. The fares for all classes are different with unreserved seating class
being the cheapest. The following table lists the classes in operation.

Figure 2 Class of Pakistan Railway

Organizational Structure

Figure 3 Organizational Structure of P.R

Pakistan Railways is a state-owned enterprise under the Ministry of Railways (MoR) of

the government of Pakistan, tasked with and primarily responsible for planning,
administrating and establishing passenger rail service and regulating railway companies and
industries. Pakistan Railways policy and development are administered by the ministry. From
1947 to 1959, the Pakistan Western Railway and Pakistan Eastern Railway were administered
by the Railway Division of the Ministry of Communications, headed by the Director General
of Railways (DG Railways) in the ministry. In 1959, an ordinance was passed
by Parliament outlining the need for a semi-autonomous railway board. The board was
conceived in accordance with the principal powers of the central government as stipulated in
the Railways Act IX of 1890. After the first session of the third national
assembly, President Ayub Khan issued Presidential Order 33 on 9 June 1962. The order

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directed the transfer of control of both railways (PWR and PER) from the central government
to the provincial governments of West Pakistan and East Pakistan, respectively. When PO 33
came into effect on 1 July 1962, railway boards were established by both provinces
(repealing the Railway Board Ordinance of 1959).

The presidential order also reinstated the separation convention whereby railway finances
were separated from general finances beginning with fiscal year 1961-62, giving each board
greater autonomy. In 1974, the Ministry of Railways was created to administer planning,
policy-making, technical advice and management of the railway. In 1982 the Ministry of
Railways was merged with the Railway Board by a presidential order, resulting in the federal
ministry.

Pakistan Railways has three functional units: operations, manufacturing and welfare and
special initiatives. The operations unit is divided into three main departments. The
Infrastructure Department oversees civil engineering, signaling, telecommunications, design
and the directorate of property. The Mechanical Engineering Department oversees
mechanical engineering, purchasing, stores and electrical engineering, and the Traffic
Department oversees passenger facilities, operations, marketing and the directorate of
information technology. Several smaller departments, including personnel, railway police,
planning, legal affairs, public relations and the Pakistan Railways Academy, are also part of
the operations unit.

Literature Review of Mughalpura Workshops

The Moghalpura Railway Workshops are one of several PakistanRailwaysrolling stock repair
sites, located on the Lahore- Wagah Line at Mughalpura 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.

Introduction of the all Department’s

He is responsible for maintenance of the rolling stock and other mechanical equipment of
the Railway. Every Railway has one or more Workshops under the control of its
Mechanical Department in which Locomotives, Carriages & Wagons are periodically
examined, repaired and overhauled before being placed back on the line.
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Section I.12

Objective

Introduction of the Tool Shop CC. 7115

Tool shop is responsible to provide cutting tools of machines and different types of dies for
railways workshops, e.g. drills, shanks for tips, dies & punches etc. there are 3 precious
machines and also 1 engraving machine.

The part of a factory where tools are made or repaired: a store that sells tools: The
spanner can be purchased at your local tool shop or DIY store.

Tools are things used to make tasks easier. Some examples of tools that are often used
today are the CNC wire cut Machine, the Forging press, Punch & Die, Lathe Machine,
and the Milling Machine. Very basic things like Shaper Machine, Plainer Machine, and
Drilling Machine are also tools.

Section I.13

Objective

Introduction of the Machine Shop CC. 7124

In machine shop section different types of machines are used to machine

different parts according to need. After casting the work pieces are machined to convert them
into various parts according to part structure. Various types of machines are available in at
C& W shop and Loco shop of railway industry to machine different parts according to part
specification (part drawing). 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.

A place where hand tools and power-driven tools are used for making, finishing, or repairing
machines or machine parts or in other words a facility that has machines, machine tools for
working with metal other relatively hard materials such as some ferrous and non-ferrous,
composites, polymers, etc.

There are different Machines used in Machine Shop that are:

1.1 Shearing Machine

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2.1 Bending Machine

3.1 Hydraulic Blanking Machine
4.1 Screwing Machine
5.1 Lathe Machine (Internal and External Threading)
6.1 Slotter Machine
7.1 Planer Machine
8.1 Shaper Machine
9.1 Milling Machine
10.1 Milling Cutters
11.1 Grinding Machine
12.1 Thread Rolling Machine

Section I.14

Objective

Introduction of the Wheel repairing Shop CC. 7124

As its name shows in this section wheels are repaired and if necessary then change the axle of
wheels or change the wheels with new set of them. The reasons why wheels and axle are
needed to be change are.

 May its thickness is less than required thickness.

 May bore of wheel is open so axle seat is not press fitted in the wheel bore.
 May axle seat’s diameter is less.
 May axle is bending.
 May rim is out from the frame (In tire wheel this is happen)

Figure 4 Wheel

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Different machines use for the given operations. After repairing the axle and dick again
mount to each other by using hydraulic press.

Section I.15

Objective

Introduction of the Lifting Shop CC. 7120 (Bearing Section)

The lifting section deals with the repair of coaches and their related arts. It is called as lifting
section because the parts of coaching cannot be repaired without lifting them. There are
three main sections of lifting.

 Roller Bearing Section

 China Coaches Section
 German Coaches section

Figure 5 Fork Lifter

Section I.16

Objective

Introduction of the Spring Shop CC. 7101

Springs are flexible machine element used for controlled application of force or torque or for
storing and release of mechanical energy. Flexibility (elastic deformation) is enabled due to
cleverly designed geometry or by using of flexible material.

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Figure 6 Spring Shop

Section I.17

Objective

Introduction of the Black Smith Shop CC. 7113

A blacksmith is a metal smith who creates objects primarily from wrought iron or steel, but

sometimes from other metals, by forging the metal, using tools to hammer, bend, and cut
(cf. tinsmith). Blacksmiths produce objects such as gates, grilles, railings, light fixtures,
furniture, sculpture, tools, agricultural implements, decorative and religious items, cooking
utensils, and weapons. There was an historical opposition between the heavy work of the
blacksmith and the more delicate operation of a whitesmith, who usually worked
in gold, silver, pewter, or the finishing steps of fine steel. The place where a blacksmith
works is called variously a smithy, a forge or a blacksmith's shop.

Section I.18

Objective

Introduction of the Air Condition Shop CC. 7308

Air-conditioning is that process used to create and maintain certain temperature, relative
humidity and air purity conditions in indoor spaces. This process is typically applied to
maintain a level of personal comfort.

It's also used in industrial applications to ensure correct operation of equipment or machinery
that need to operate in specific environmental conditions or alternatively to be able to carry
out certain industrial processes, such as welding, which produce considerable amounts of heat
that needs to be disposed of in some manner.

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An air-conditioning system must be effective regardless of outside climatic conditions and

involves control over four fundamental variables: air temperature, humidity, movement and
quality.

The distinction between industrial and personal comfort applications is not always clear cut.
Industrial air-conditioning usually requires better precision as regards temperature and
humidity control. Some application also demand a high degree of filtering and removal of
contaminants.

Comfort air-conditioning on the other hand, as well as needing to satisfy personal

temperature-humidity requirements, also involves other fields such as architectural design,
weather forecasting, energy consumption and sound emissions to recreate the ideal conditions
for human psychophysiological well-being.

The main process underlying air-conditioning is the exchange of heat and water vapors
between the indoor and outdoor environments and the people inside the air-conditioned
space. 

The principal appliances used in home and industrial air-conditioning are:

 Packaged, split or multi-split air-conditioners for home use;

 Residential heat pumps;
 Air handling units for medium/large spaces;
 Rooftop units, air handling units for small spaces;
 Shelter units, air-conditioner for telephone exchanges;
 Industrial chillers and heat pumps, units that produce chilled or hot water that's then
used air-condition the environment or equipment;
 Close control units, precision cooling units for servers or telecoms equipment;
 Fan coils and hydraulic systems, systems using chilled water circuits and terminal
units for air-conditioning buildings.

These differ significantly in terms of size, complexity and cooling capacity, which may range
from several hundred watts into the megawatts, components and in general which of the main
air-conditioning functions are implemented, i.e.:

 Cooling of air or water;

 Heating of air or water;
 Air dehumidification;

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 Air humidification;
 Air filtering/purification;
 Mixing of air indoor/outside air;
 Ventilation.

Figure 7 Internal view of AC Coach

Home air-conditioners, for example, mainly cool the air taken in from the air-conditioned
space in a closed circuit. Such cooling also dehumidifies the air as some of the moisture this
contains condenses inside the air-conditioner (in the form of droplets) and is then collected
and discharged outside via a rubber hose.

Section I.19

Objective

Introduction of the Power Plant Shop CC. 7551

The diesel engine produces mechanical energy by converting heat energy derived from
burning of fuel inside the cylinder.

For efficient burning of fuel, availability of sufficient air in proper ratio is a prerequisite.In a
naturally aspirated engine, during the suction stroke, air is being sucked into the cylinder
from the atmosphere. The volume of air thus drawn into the cylinder through restricted inlet
valve passage, within a limited time would also be limited and at a pressure slightly less than
the atmosphere. The availability of less quantity of air of low density inside the cylinder
would limit the scope of burning of fuel.
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Hence mechanical power produced in the cylinder is also limited.
During the suction stroke, pressurized stroke of high density is being charged into the
cylinder through the open suction valve. Air of higher density containing more oxygen will
make it possible to inject more fuel into the same size of cylinders and produce
more power, by effectively burning it. A turbocharger, or turbo, is a gas compressor used for
forced-induction of an internal combustion engine. Like a supercharger, the purpose of a
turbocharger is to increase the density of air entering the engine to create more power.
However, a turbocharger differs in that the compressor is powered by a turbine
driven by the engine's own exhaust gases.

Section I.20

Objective

Introduction of the Machine Shop CC. 7005

In machine shop section different types of machines are used to machine

different parts according to need. After casting the work pieces are machined to convert them
into various parts according to part structure. Various types of machines are available in at
C& W shop and Loco shop of railway industry to machine different parts according to part
specification (part drawing). 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.

Section I.21

Objective

Introduction of the Foundry Shop CC. 7001

In foundry shop different types of parts are produced using casting process. 

After casting the work pieces are machined to convert them intovarious 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.

Operation are performed according to the sequence mentioned on work order.

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SWOT Analysis of Pakistan Railway

Strengths

 Railway schools and Colleges

 Hospitals
 Law court with its own Magistrate
 Own Electricity Production Unit.
 Own huge Land Property (167690 Acres)
 Fuel Consumption.

Weaknesses

 Manually work
 Railway service
 Overloaded Trains
 No proper check of tickets
 In-efficiency of staff.

Opportunities

 In addition to above. Twenty reservation offices have been planned to be computerized.

Jacobabad, Mirpur Khas, Jahangir Road Mehrabad, Jheulm, Sargodha, Malakwal,
Shorkot Cantt, Nowshera, Lalamusa , Bhakkar, Pakpattan, Kundian, Wazirabad, Toba
Tek Sing, Kasur, Raiwind ,Chiniot, Landhi, Tando Adam.

Threats

 Other comfortable vehicles

 Shipment facility
 Earning of Pakistan Railway
 Expenditures.

Critical Analysis

Pakistan Railways started its operations with 8,122 kilometers of railway tracks in the year
1947 [29]. At the initial stage, the overall capacity of railways was limited to provide a better
transport facility to the customers. From 1948, railway industry improved its service quality,
people used to travel with railways, and usage of railways increased. Data related to railway
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industry was available from the year 1950 to 2015; therefore the year 1950 was used as
starting or base point to examine and study the development trends. For this paper, data were
collected from Pakistan Railway Year Book 2014-15 and SPSS software was used for
statistical analysis. At the initial stage, seven indicators, passenger volume, average passenger
mileage, passenger turnover, freight volume, average freight mileage, freight turnover, and
number of employed persons, were included for the analysis.

Conclusion

This training focused upon increasing our knowledge and interest into ward the Production of
Railway Carriage & Wagons and Locomotive 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 fruit full.

Finally I would like to thanks all the person of this organization who had helped me lot
during my training.

Future Recommendations about Pakistan Railway Workshops

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 inany specific
consideration. The positive ness heavily depends on the individual’s education and curiosity.

Railway department should upgrade its system of transferring the letters, applications and
other various documents to its other departments i.e. by use of internet technology.

It must use the banking transection system for the comfort of people and more safety of its
cash.

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As most of the machinery systems are installed since 19th century, so railway department
ought to revolutionize its system (with the latest ones) in order to compete with the modern
railway industries of the world.

Latest methods and techniques should be adopted for the up gradation of the previous ones,
for example the check and balance of all the worker’s work should be more regulated along
with the use of biometric attendance system, for the advancements in work.

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.

As we know that Railway sector is most important for Pakistan Economy, but now a days
Railway face many problems which we discussed in this report. If we focus on Railway
problems and try to solve these problems then our economy growth is increased. Following
are some of the suggestions and recommendations that I want to give based on shortfalls /
weaknesses found in the Pakistan Railway.

 Improve infrastructure.
 Introduce new technology.
 New investment plans are introduced.
 Land of Railway used for new projects.
 Regular staff meeting
 Encourage Brainstorming.
 Everyone accountable for their work.

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 The Railway should emphasis on the organization of effective training and development
programs for its new as well as existing employees so that these are gradually
updated regarding the recent developments in the field of Railway sector.

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