PREFACE

This report is based on the in-plant training of the first six month of National Diploma in

Technology- University of Moratuwa.

My training place was Sri Lanka Railway workshop Ratmalana. They are doing locomotive

repairing and maintenance and manufacture locomotive parts. I was in four electrical workshops.

When I was there I could be able to get vast knowledge. Mainly locomotive and industrial

electrical works. This report gives a brief description of working experience with theoretical things

which I got in my training period.

This report contains four chapters. The organizational structure of the Sri Lanka Railway

Department is described as the introduction in first chapter. Second chapter describes my

experience I had gained during my training period. Then I was added the suggestions I have made

to maximize the efficiency of the workshops and the conclusion which includes a summary of the

training period as the third chapter. Finally the leave record form, training schedule and annex G

are added as in chapter four.

1

ACKNOWLEDGEMENT

My special thank must go to,

All of the academic staff members of Department of Electrical Engineering Technology of

ITUM for afforced with theoretical knowledge in myself and my colleagues.

Mr.R.Perera, Training Engineer of Industrial Training Division of ITUM

Staff of National Apprentice & Industrial Training Authority (NAITA)

Mr.A.D.Wickramasinghe, Training Operation Manager of Sri Lanka German Railway

Technical college and Staff.

All foremen and supervisors of CGR electrical workshops 31 , 35 , 30 , and 39 and

Technicians and rest of the staff helped me to gather deep knowledge and experiences

All of the workshop workers who supported to me for completed my training period

successfully.

My colleagues who had trained with me as electrical and mechanical engineering technology,

for helping me when I was in difficulties and making enjoyable successful training period

W.L.Mahesh

Instutute of Technology

University of Moratuwa.

CONTENTS

2

CHAPTER 01

Introduction …………………………………………………………………..…….………05

CHAPTER 02

AC Motor Rewinding............................................................................................................ 09

Trouble shooting of “Seieere” water pump motor……............................... 12

Cutting grinder machine troubleshooting.............................................................................. 12

Commutator Repair................................................................................................................13

Air conditioner troubleshooting.............................................................................…............14

Air conditioner cleaning ………........................................................................................... 15

Armature balancing………………………………………………………………………....16

Safety and Quality Assurance ……………………………………………………………...17

CHAPTER 3

Suggestions ………………………………………………………………………………... 18

Conclusion …………………………………………………...…………............................. 19

CHAPTER 4

Annex D ................................................................................................................. .. 20

Annex F....................................................................................... ......................21

Annex G.............................................................................................................. 22

INDEX

3

Fig 1: Burned stator winding removing ……………………………………..………………………...

09

Fig 2: cleaned Stator ………………………………………………………………………………….

10

Fig 3: painted stator against corrosion………………………………………………………………..

10

Fig 4: winding former………………………………………………………………………………....

10

Fig 5: removed coils for take details…………………………………………………………………..

10

Fig 6: Stator winding installation …………………………………….................................................

11

Fig 7: Making stator winding connections………………………………………………………….

11

Fig 8: Angle cutting grinder …………………………………………………………………………..

12

Fig 9 : Commutator …………………………………………………………………………………...

13

Fig 10: mica undercutting …………………………………………………………………………….

13

Fig 11: thermostat ………………………………………………………………………………….....

14

Fig 12: : condenser cleaning …………………………………………………………..……….......…

15

Fig 13: rotor at the balancing machine ……………………………………………………...……..…

16

Fig 14: Control panel of armature balancing machine…………………………………………..

……. 16

4

CHAPTER 01

INTRODUCTION

Sri Lanka Railway (SLR) workshop is the sub department (Main Mechanical

Engineering Sub Department) of the Sri Lanka Railway Department under controlled by the

General Manager of Administration (GMA). The highest designation of the SLR workshop is Chief

Mechanical Engineer (CME). The purposes of the railway workshop are well maintaining and

overhauling of the locomotives, carriages & wagons.

CME Sub Department

5

Organizational Structure of Sri Lanka Railway Department

6

CME

DME

MEC MES

FOREMAN

TKC

SUPERVISOR

1ST CLASS TECHNICIAN

2N

D CLASS TECHNICIAN

3RD CLASS TECHNICIAN

LABOURS

TRAINEES

MEF MEP MEU MEL (E)

MEL (H)

MEL (P)

MED

GMR - General Manager of Railway

7

GMR

GMT GMAMain Mechanical Engineering

Sub Department

Main Motive Power Sub Department

Main Way & Works

Engineering Sub

DepartmentSignal & Telecominicati

on Sub Department

Transportation Superintendant

Commercial Superintendant

Chief Accountantof

Railway

Sales Manager

Sri Lanka Railway

Superintendant

Sri Lanka railway force

superintendantSri Lanka German Railway

Technical Training Centre

GMO

GMT - General Manager of Technical

GMA - General Manage of Administrative

GMO - General Manager of Operation

CME - Chief Mechanical Engineer

DME - Deputy Mechanical Engineer

CEE - Chief Electrical Engineer

MEC - Mechanical Engineer of Carriage

MEW - Mechanical Engineer of Wagon

MEF - Mechanical Engineer of Foundry

MEP - Mechanical Engineer of Production

MED - Mechanical Engineer of Drawing

MES - Mechanical Engineer of special project

MEL (E) - Mechanical Engineer of Locomotive (Electrical)

MEL (H) - Mechanical Engineer of Locomotive (Hydraulic)

MEL (P) - Mechanical Engineer of Locomotive (Power)

EEC - Electrical Engineer of Carriage

EET - Electrical Engineer of Traction

EEP - Electrical Engineer of power

TO - Technical Officer

BDF - Building Department Foreman

TKC - time keeper clerk

SK - Store Keeper

RBP - Railing Bus Project

There are both Electrical and Mechanical work shop under controlling Chief mechanical and electrical engineer. But in earlier there was not a chief electrical engineer post. It that period all electrical work shop were maintained and inspected by Ceylon electricity board. Now the administration under took by chief electrical engineer and other there sectional engineers there are,

Electrical engineer carriage. (E.E.C) Electrical engineer traction. (E.E.T) Electrical engineer power. (E.E.P)

8

Also the training students are under trained by the Workshop Forman. The all the workshops are works with together to well maintenance of the locomotives, railroads and the carriages & wagons. According to our training schedule we have four numbers of workshops to our practice.

Workshop 31- AC motors and AC Generators maintains , AC machine rewinding, Ceiling

fan rotor rewinding and Grinder, Grill armature rewinding and maintains , Transformers

rewinding and maintain.

Workshop 35- DC Electrical machines maintained rewinding and repair electronic controls

of Traction motors.

Workshop 30- Battery repairs ,Carriage wiring, Air condition repairs and electroplating

Workshop 39-. Heavy AC and DC Generators, Traction motors, DC traction controls, and

control cubical works, Armature repairs and Armature Balancing.

CHAPTER 2

9

AC Motor Rewinding

We make a rewind for “Khaithan Exhaust Fan” single phase induction motor. Name plate

data of that motor is following.

230V, 2.3A, 500W , 50Hz , 900 rpm

Slots-36

Coil diameter- 600nm

Coil sets- 6

Starting Winding turns- 148, 73 (two coils per one set)

Running Winding turns- 128, 65 (two coils per one set)

Coil pitch- 1/5, 1/7

Winding style- top-top , Bottom-Bottom

First we check windings conductivity using a bulb circuit. W found some burned windings

and decide to remove all windings and make a rewind.

When we remove old windings, we took its data.( no of turns, oil pitch, diameter, and

connection configuration.)

For remove winding easily, we burned stator with coils in oven at 60°C.

Then we cleaned stator core using thinner and knife. Then applied anti-cross paint against

corrosive.

10

Fig 1: Burned stator winding removing

Then we choose a suitable former for rewinding, using taken data. And made windings using winding machine according to details.

11

Fig 2: cleaned Stator Fig 3: painted stator against corrosion

Fig 4: winding former Fig 5: removed coils for take details

then we prepare insulator papers for stator slots. we used combine papers for that. And then inserted coils to slots very carefully. We specially mentioned about coil’s turn side. All coils must be a one side. Also some enough length of coil at end and at start released for connection purposes.

For insert coils, we used special tool made using PVC. It is very useful for insert coil to slots without damages.

When we insert second coil (running winding) to slots, it is very difficult because there was not enough space for that. Therefore we used rubber hammer for tight the coils.

Then made connections according taken data. then insulate joints and cable using sleeves.

Then

12

Fig 6: Stator winding installation

Fig 7: Making stator winding connections

Then applied insulation salac and burned in oven at 90 °C.

After that checked windings again using bulb circuit.

At last, sent it to workshop 35 for reassemble.

Troube shooting of “Seieere” water pump motor

It is single phase 1KW induction motor. The problem is failure to start.

First we checked fuse and circuit breakers. Those are OK.

Then check connections and mega ohm tested.

Then cheked the starting capacitor using another motor. It is not working properly. Then set new 400v, 10µF capacitor . Then the motor is started. But it a noise. We observed bearing temperature is very high. Then we change the bearing and check again.

Cutting grinder machine troubleshooting.

It

It is DEWALT, 20000rpm, 800W angle cutter machine.

13

Fig 8: Angle cutting grinder

First we open the case of machine and carefully removed the brushes from the brushine holder.those were wear. Replace new brushes, because those were not matched with machine. Then we made those brushes shape using Amery paper according to old ones.

Then assemble it by feeding the wire to the pin and twist .then placed the brushes.

Commutator Repair:

In DC machines, when replacing brushes, we checked commutator for wear and damages. If commutator is worn down more than 1/32 inch on the diameter or is pitted, we have to turning it and after undercutting also.

First we mounted the armature on lathe machine and align the armature. We used diamond tool as a cutting tool. Then Turning and facing the commutator carefully using automatic cutter running mode.

The following tolerances can be achieved:

Bar to bar deviation =          .0001” (.00254mm)

T.I.R. =      .0003” (.00762mm)

Surface finish:

Single cut =       32 micro inch (0.8 micro meter)

Double cut =      16 micro inch (0.4 micro meter)

14

Fig 9: Commutator

Now, no clearance between two commutates parts because of the turning. Therefore we

made its clearance using steel blade. That is the mica undercutting. After undercutting, we

polish the commutator using very thick emery paper.

Air conditioner troubleshooting

It is LG 11,500 BTU Air Conditioner at a office.

First we checked the thermostat was set to “cool” and that the set temperature was well

below the ambient temperature. Then we checked the main electrical panel and other

secondary circuit panel for a tripped breaker or blown fuse, but not found. Then we

checked the furnace power switch was turned on and that the outdoor condenser’s power

switch, which is mounted on the outdoor unit, hasn’t been shut off. Also checked the 240-

volt disconnect next to the compressor, which is in a metal box usually mounted on the

house wall, hasn’t been shut off.

15

Fig 10: mica undercutting

So then remove the cover and checked the thermostat. Removed the thermostat’s cover

and unscrew the wire from the terminal. then turn the power back on. Holded the wire by

its insulation only, touched the bare end to the another terminal and hold it there for about

two minutes. The compressor is kicked on. It means the thermostat is faulty. then we

replace it and checked again. The problem was fixed. But not cooling.

Air conditioner cleaning

A central air conditioner that runs but doesn’t cool may just need to be cleaned.

First we raked leaves and debris away from the outdoor condenser. Then trim bushes that

might block airflow.

16

Fig 11: thermostat

Fig 12: condenser cleaning

Then unscrew and removed protective grilles and the top cover from the compressor. The

fan is attached to the grille, therefore we carefully for not to pull any wires loose.

Then used a soft brush to clean dirt and debris from the fins, and then vacuum the fins with

a brush attachment.

From inside the unit, we used a hose and nozzle with a trigger grip to spray debris from

the fins (protect the wiring and motor with plastic sheeting or a large plastic garbage bag).

Then reassembled the parts and powered. It started works properly.

Armature Balancing

In work shop 39 they used Dynamic Balancing Method for armature balancing. When the motor

vibrate due to unbalanced armature, armature balance is essential. The procedure of dynamic

balancing using fully automatic machine is following.

• Place rotor on to the bearing of the machine.

• Then Close counter Support

• Set belt around the rotor for running.

• Set electronic metering units in accordance with rotor dimensions, balancing

speed.

• Set , black point indicator with white paper to the rotor.

17

Fig 13: rotor at the balancing machine

• Set the sensor and degree scale around rotor.

• Switch on driving motor.

• Start drive and run the rotor, up to balancing speed.

• Take and retain the reading.

It gives wanted weights at suitable degree points according to degree scale. Then we measure

resulted weights (iron pieces) using electronic balance and fix those at given points.

Safety:

CGR has very wide fire protection system. It has all instruments and vehicles for the fire.

But all workshops haven’t good rain water proof method. In April, May this year all workshops fill

in rain water and large no of Instruments and machines destroy because of the water.

Workers do not use safety helmets and boots, grouses etc... Large Cranes with many tons of

weights always go on workers heads.

Worker have no good safety methods for working with electrical goods.

Quality Assurance

All workshops use 5S methods. But in practically it is not very successful.

Because have to handle very heavy and large Items, engines and some workshops have no much

space and also some workshops are so busy. And main thing is workers have no idea about quality

assurance.

18

Fig 14 : Control panel of armature balancing machine

CHAPTER 3

SUGGESTIONS

• Make practically success regulations and rules.

• Built good Quality assurance system

• Stop political placements

• Use new technologies.

• Make good communication system

Stop the political coercion and the appointments in the workshop.

Take employers and giving promotions for them according to the organization rules. Also

give opportunity to young person with better experience for join the higher designations in

Sri Lanka Railway Department.

19

Organize new technologies workshops for Formans and Technicians..

Give the instructions about the employee’s safety and advice them to follow the safety

instructions. Also introduce the new technology.

Make good travelling system within the workshop

Remove all unnecessary parts and carriages from workshop area.

Additionally that, I would like to request about the following things as the training student.

Make our schedules with good balance with both production and automobile sections.

Give us opportunity to borrow the manuals of the machines, locomotives and their

components, from the technical library.

CONCLUSION

As a student we can ask any question from workshop foreman and even from workers. No

one try to neglect us. But if we ask question after that, it may cause to lower the quality of our

profession. After my first industrial training I can improve my knowledge about the production

field.

We have technical background. We learnt lot of theories in the institute and didn’t see the

application of those. But during first industrial training period we saw how it can be used our

theoretical knowledge for practical applications.

The seminar held by the NAITA prior to the training and held in Campus by training engineer was

valuable things.

All of the workers in the workshops were really helpful to me by guiding to get working experience

and educating me to get knowledge about some are new for me. Also the resources that were

available to me were very satisfactory.

20

In my training session I not only gained the technical knowledge and also got the knowledge about

how to dealing with working environment, how to dealing with the officers & the workers, how to

maintaining the stocks in the workshops and their importance.

Finally, I think my first training period is I finished very successfully and I am very satisfactory.

CHAPTER 04

Annex D

LEAVE RECORD FORM

To be sent by registered post to Head of Industrial Training, Institute of Technology, University of Moratuwa after completing each six month period.

1. Name of Trainee: W.L.Mahesh

2. Industrial Training: 1 st six months

(1st six months / 2nd six months)

3. Training Establishment: Sri Lanka Railway Workshop, Ratmalana

4. Leave Record

1st Month 2nd Month 3rd Month 4th Month 5th Month 6th Month

21

No. of days on Leave

- 2 1 2 1

5. Has the leave been approved by the Establishment: Yes

Date:

Signature of Trainee

Note: This is mainly for the information of ITUM and not to replace the standard leave application form, which has to be forwarded to the organization.

Annex G

CONFIDENTIAL

NATIONAL APPRENTICE AND INDUSTRIAL TRAINING AUTHORITY 1 ST SIX MONTHS / 2 ND

SIX MONTHS ASSESSMENT OF N.D.T. APPRENTICE 2010

Place of Assessment: …………………………………. Date of Assessment: ………………...... …………………………………. Time: ………………….

Field: ………………………………………………………

Serial

No.Name

Assessment element

Remarks

Da

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Pro

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x5)

Fin

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um

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Rel

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Ind

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& L

ab

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TO

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FA

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15 10 20 40 10 05 100

1.

2.

3.

22

4.

5.

6.

7.

8.

9.

10.

11.

12.

NAME OF EXAMINER DESIGNATION SIGNATURE

1.

2.

3.

4.

5.

23