SESHASAYEE INSTITUTE OF TECHNOLOGY

Autonomous
(AN ISO 9001:2008 CERTIFIED INSTITUTION)
ARIYAMANGALAM,
TIRUCHIRAPPALLI – 620 010

DEPARTMENT OF MECHANICAL ENGINEERING

3F 6405 –PROJECT WORK AND INTERNSHIP

INTERNSHIP REPORT- (2023 -2024)

Name – K.GANESHRAJAN

Register Number – 211316

Year & Term -- III & VI

Name of the Company – DIESEL LOCO SHED

Duration of Internship -- 12 DAYS (15-05-23) to (27-05-23)

 SESHASAYEE INSTITUTE OF TECHNOLOGY
Autonomous
(AN ISO 9001:2008 CERTIFIED INSTITUTION)
ARIYAMANGALAM,
TIRUCHIRAPPALLI – 620 010

DEPARTMENT OF MECHANICAL ENGINEERING

3F 6405 –PROJECT WORK AND INTERNSHIP

INTERNSHIP REPORT- (2023 -2024)

Name – K.GANESHRAJAN

Register Number – 211316

Year & Term -- III & VI

Name of the Company – DIESEL LOCO SHED

Duration of Internship -- 12 DAYS (15-05-23) to (27-05-23)

 TABLE OF CONTENTS

Contents Page no

 DO’s & DON’T’s -------------------------------------------04

 OBJECTIVES OF THE INTERNSHIP ------------------05

 BENEFITS OF INTERNSHIP---------------------------- 06

 COMPANY PERMISSION LETTER--------------------07

 COMPANY CONFIRMATION LETTER---------------08

 SCHEDULE--------------------------------------------------09

 CERTIFICATE----------------------------------------------10

 ATTENDANCE REPORT---------------------------------11

 REPORT-----------------------------------------------------13
 DO’s & DON’T’s

Do’s:

Student interns should…

 Understand the company and industry in which they are placed.

 Formal dress code is mandatory exclaimed.

 Maintain cordial relationship and be polite with company executives.

 Be in touch with the faculty guide always and consult him/her to reinforce
the relevant concepts.

 Maintain strict confidentiality of the company’s information.

 Be present whenever the faculty guide is the internship coordinator or any

other institute officials visit the company.

 Concentrate on assignments and complete the allotted individual task on

time.
Don’ts:

 Should not attend the office in informal dress.

 Should not be late.

 Should not be impolite or rude to the company executives.

 Should not criticize the company’s policies and the company executives.

 Should not misuse the facilities offered by the company.

 Should not leave the office without prior permission from the company
guide.

 Should not borrow money or any other personal effects of the company
executives.
 OBJECTIVES OF THE INTERNSHIP

Internships are educational and career development opportunities, providing

practical experience in field or discipline. They are structured, short - term,
supervised task often focused around particular tasks or projects with defined
timescales. The internship has to be meaningful and mutually beneficial to the
intent and the organization. Following are the intent objectives of internship
training:

 Will expose technical students to the industrial environment, which cannot

be stimulated in the classroom and hence creating competent professionals
for the industry.
 Provide possible opportunities to learn understand and sharpen the real time
technical / managerial skills required at the job.
 Exposure to the current technological developments relevant to the subject
area of training.
 Experience gained from the ‘Industrial Internship’ will be used in classroom
discussions.
 Create conditions conducive to quest for knowledge and its applicability on
the job.
 Learn to apply the technical knowledge in real industrial situations.
 Gain experience in writing technical reports / projects.
 Expose students to the engineer’s responsibilities and ethics.
 Familiarize with various materials, processes, products and their
applications along with relevant aspects of quality control.
 Promote academic, professional and / or personal development.
 Expose the students to future employers.
 Understand the social, economic and administrative considerations that
influence the working environment of industrial organizations.
 Understand the psychology of the workers and their habits, attitudes and
approaches to problem solving.
 BENEFITS OF INTERNSHIP

Benefits to the industry Benefits to the students Benefits to the institute

1) Availability of ready 1) An opportunity to get 1) Build industrial
to contribute candidates hired by the relations.
for employment. industry/organization...
2) Makes the placement
2) Year-round source of 2) Practical experience in process easier.
highly motivated pre- an organizational setting.
3) Prove institutional
professionals.
3) Excellent opportunity credibility and branding.
3) Students bring new to see how the theoretical
4) Curriculum revision
perspectives to problem aspects learned in class.
can be made based on
solving.
4) On floor experience feedback from industry /
4) Visibility of the provides much more students.
organization is increased professional experience
5) Improvement in
on campus. which is often worth
teaching learning
more than the classroom
5) Quality candidate’s process.
teaching.
availability for
6) Number of placements
temporary or seasonal 5) Helps them decide if
may increase.
positions and projects. the industry and the
profession is the best 7) Opportunity to
6) Freedom for industrial
career option to pursue. establish incubation
staff to pursue more
centre on campus.
creative projects. 6) Opportunity to learn
new skills and 8) Consultancy projects
7) Availability of
supplement knowledge. may be attracted.
flexible, cost effective
work force not requiring 7) Opportunity to
a long term employer practice communication
commitment. and teamwork skills.
8) Proven, cost effective 8) Opportunity to learn
way to recruit and strategies like time
evaluate potential management
employees. multitasking etc.., in an
industrial setup.
9) Enhancement of
employers image in the 9) Opportunity to meet
community by new people and learn
contributing to enterprise networking skills.
COMPANY PERMISSION LETTER
COMPANY CONFIRMATION LETTER
SCHEDULES
CERTIFICATE
ATTENDANCE REPORT
 DIESEL LOCO SHED
PONMALAI, TRICHY

Diesel Loco Shed, Golden Rock is an engine

shed located in golden rock Tiruchirappalli, Tamil nadu in India. It is
located north of Golden Rock railway station, falling under
Tiruchirappalli railway division. It is the largest of the four
locomotive shed under the Southern Railway zone of Indian
Railways.
HISTORY OF DIESEL LOCO SHED:

The foundation stone for the shed was laid

on the 25th of December, 1971 by the Railway minister. The
shed was open for operations in 1975 with a total area of
169,000 square meters (170,000 m2) and covered area of
19,600 square meters (20,000 m2).
The shed initially homed 45 of the YDM-4
class meter gauge locomotive. Three subsequent expansions
were taken up which resulted in the holding capacity being
increased to 100 meter gauge locomotives (1998), 40 broad
gauge locomotives (1993) and 100 broad gauge locomotives
(2000)

INFRASTRUCTURE:
The shed was started as a meter-gauge
shed. However with expansion over time, the bays and
catwalks were converted from meter gauge to broad-gauge
standards to home broad-gauge locomotives.
Later, the shed went for a major expansion
of its bays at a cost of ₹14 crore (US$1.8 million) to
undertake maintenance activity for the unconventionally
longer high-speed fuel efficient 4,500-horsepower (3,400KW)
locos (WDP-4D ,WDP-4B ,WDP-4 and WDG-4D)The shed
was started as a meter-gauge shed.

LIST OF SERVICE LOCO IN PONMALAI:

  American Locomotive (ALCO)
 High Horse Power (HHP)
 Diesel Electrical Multiple Units (DEMU)

High Horse Power (HHP) an HHP locomotive, or High Horsepower

locomotive, is a type of railway engine that is designed to generate a high level
of power in order to pull heavy loads.

Diesel Electrical Multiple Units (DEMU) Diesel Electric

Multiple Units are self-propelled units consisting of Driving. Power Car and
Trailer Cars. They have been developed to give faster service for suburban areas
where traffic density is high.
American Loco (ALCO) The American Locomotive Company (often
shortened to ALCO or Alco) was an American manufacturer of locomotives,
diesel generators, steel, and tanks that operated from 1901 to 1969

These types of locomotives are typically used in freight transportation and

mining operations, where the ability to move large quantities of materials over
long distances is essential. They are also used in some passenger trains,
specially designed for high-speed rail.

LIST OF DIESEL LOCO MOTIVE:

Under the new system, the fifth letter further refines horsepower in 100-hp
increments: A for 100 hp, B for 200 hp, C for 300 hp and so on. A WDP-3A is a
3,100 hp (2,300 kW) locomotive, and a WDM-3F is 3,600 hp (2,700 kW).

 WDM – Wide diesel mixed

 WDP – Wide diesel passenger
 WDG – Wide diesel goods
 WDS – Wide diesel shunte

I’m K.GANESHRAJAN Studying III year Diploma in Mechanical

Engineering at Seshasayee Institute of Technology, Trichy-10.
 DAY 1 [15.05.2023]

AIR BRAKING SYSTEM

In Air Brake System compressed air is used for
operating the brake system. The locomotive compressor charges the
feed pipe and the brake pipes throughout the length of the train. The
feed pipe is connected to the auxiliary reservoir and the brake pipe is
connected to the brake cylinder through the distributor valve.

The air brake system has the following main components,

 Compressor
 Main reservoir tank (MR1)
 Main reservoir tank (MR2)
 Air dryer

Types of air braking systems:

 28-LV-1 (Pure vacuum) It is used in meter gauge loco’s.

 28-LAV-1 (Vacuum +Air) It is used in broad gauge loco’s.
 IRAB ( Pure Pneumatic air )
  CCB ( Compressed air )

There are five positions in the Auto brake unit:

 Release
 Run
 Minimum
 Full service
 Emergency

Air brake systems are widely used in commercial vehicle such as

truck, bus, trains etc. Railway vehicles are commonly equipped with
braking systems using compressed air to push the pads on the discs or
blocks to the wheels. The systems are known as air or pneumatic
brakes.
 DAY 2 & 3 [16.05.2023, 17.05.2023]
POWER PACK
A “diesel” internal combustion engine uses the heat
generated from the compression of air during the upward cycles of the
stroke to ignite the fuel.

This is the main power source for the locomotive. It

comprises a large. Cylinder block, with the cylinders arranged in a v-
shaped arrangement. (Generally v-12 or v-16).

The main components of an IC engine include:

1. Cylinder: A cylindrical chamber in which the fuel is burned and

energy is converted into mechanical work.
2. Piston: A reciprocating component that moves inside the
cylinder and helps to convert energy from the combustion
process into mechanical motion.
 3. Crankshaft: A rotating shaft that converts the up-and-down
motion of the piston into rotary motion, which can be used to
power other systems.
4. Connecting Rod: A component that connects the piston to the
crankshaft and helps to transmit energy from the piston to the
crankshaft.
5. Valves: Openings in the cylinder head that allow fuel and air to
enter and exhaust gases to exit.
6. Fuel Injector: A device that injects fuel into the combustion
chamber.
7. Camshaft: A rotating shaft that controls the opening and
closing of the valves.

The four stroke V-typed engine is used in

the Alco Loco’s and there are 16 cylinders. Two stroke V- type
Engine is used in the HHP Loco’ also having 16 cylinders.

DAY 4 [18.05.2023]
FUEL INJECTION PUMP AND GOVERNOR

The main purpose of a fuel injection system or pump is to

deliver fuel to the cylinders of a diesel engine, but the process of
delivering the fuel impacts the engine performance, emissions and
engine noise characteristics.
A micro controller controlled DC stepper motor is used to control the
fuel rack of diesel engine of the locomotive.
The basic function of governor is speed control of engine, based on
the throttle handle position (notch).
In the four stroke engine (ALCO) locos have 9 holes in the nozzle.
The two stroke engines (HHP) loco’s have 7 holes in the nozzle.
 DAY 5 [19.05.2023]
PUMP AND BLOWER
There are two types of pumps using in Loco’

 Water pump
 Lube oil pump

 The pump is used to supply the water and lube oil to all the
engine parts.
 The gear pump is used to supply the lube oil to the engine.

Use basic forces of nature to move a liquid. As the

moving pump part (impeller, vane, piston diaphragm, etc.) begins to
move, air is pushed out of the way.

The movement of air creates a partial vacuum (low

pressure) which can be filled up by more air, or in the case of water
pumps, water.
 DAY 6 & 7 [20.05.2023, 21.05.2023]
TURBO SYSTEM
A turbocharger on a diesel Loco Motive is a device used to
generate more horsepower from the locomotive's diesel engine, also
known as the prime mover.
It uses the engine's hot exhaust gases to drive a compressor
which forces more air into the intake manifold.

There are two types of turbo system:

 The Alco loco’s (Four stroke engine) uses the turbo charger
which is driven by the exhaust gases.
 The HHP loco’s (Two stroke engine) uses the turbo super
charger which is driven by gear or belt or chain drives.

The loco’s required more air when the notches changes to 5 Speed.
 DAY 8 & 9 [23.05.2023, 24.05.2023]
CYLINDER HEAD
The cylinder head is a three-piece assembly consisting of a
lower member that contains the gas passages, serves as a mounting
for the injector valves and the ignition plug, and forms part of the
combustion chamber.
The camshaft remains in the block however the valves are
located in the cylinder head above the combustion chamber.

Main components for Cylinder Head:

 Inlet and outlet ports of the cylinders.

 Valve control.
 Injection valves.
 Injection nozzles.

The valves are acts as gates in the engine

cylinder. The fresh charge enters into the cylinder through inlet
valves. Exhaust gases are forced out of the engine cylinder through
the exhaust valves. The opening and closing of the valves are
controlled by cams. Cams are provided on the crankshaft.
 DAY 10 & 11 [25.05.2023, 26.05.2023]
UNDER TRUCK
A standard railway vehicle will have two bogies,
generally located near the vehicles ends.
Each bogie is a 4-wheeled or 6-wheeled truck that
provides the support for the vehicle body and which is used to provide
its traction and braking. The following type bogies have important
parts namely,
1) Centre pivot pin
2) Compensating beam
3) Frame
4) Helical spring
5) Suspension
6) Traction motor

The bogie frame: This can be of inside frame type where the main
frame and bearings are between the wheels, or (more commonly) of
outside frame type where the main frame and bearings are outside the
wheels. Suspension to absorb shocks between the bogie frame and the
rail vehicle body. Common types are coil springs, leaf springs and
rubber airbags.
 The centre pivot pin makes the connection to the Engine body and
to the bogies.

Traction motors are powered by electricity and generate the power

to rotate the wheels of the train.
The turning force produced by traction motors is transmitted to the
wheels via the driving gear unit and axle. Traction motors are
typically mounted in the trucks where the wheels are housed.
A small bull gear on the end of the motor and the bull gear are
meshed into the large spur gear on axle of the wheel. The motor
allows driving the train speed up to 140 Km/hr.
 DAY 12 [27.05.2023]
HEAT EXCHANGER
Heat exchangers are used to transfer heat from one
medium to another. These media may be a gas, liquid, or a
combination of both. The media may be separated by a solid wall to
prevent mixing or may be in direct contact.
Heat exchangers are required to provide heating and or
cooling to meet a process requirement.

Type of Heat Transfer:

 Radiation.
 Conduction.
 Convection.

The radiator is used to cool the water of the

engine cooled hot water by using radiator fan. When the temperature
of the water change to 67℃ the radiator fan rotates automatically.
 The internship opportunity I had with Diesel Loco Shed,
Ponmalai was a great chance for learning and professional
development.

I am also grateful for having a chance to meet so many

wonderful people and professionals who led me though this inplant
period. We thank our college for giving us permission and motivating
us for the inplant training.

THANK YOU!!

Your’s obediently,

K.GANESHRAJAN [211316].
 SESHASAYEE INSTITUTE OF TECHNOLOGY
Autonomous
(AN ISO 9001:2008 CERTIFIED INSTITUTION)
ARIYAMANGALAM,
TIRUCHIRAPPALLI – 620 010

DEPARTMENT OF MECHANICAL ENGINEERING

INTERNSHIP REPORT- ( 2023 -2024 )

Name – K.GANESHRAJAN

Register Number – 211316

Year & Term -- III & VI

Name Of The Company – DIESEL LOCO SHED

Date Of Internship -- 12 DAYS (15-05-23) to (27-05-23)

Staff in – charge Head of department

Submitted for the practical examination held on………………………………………

External Examiner Internal Examiner