PREFACE

This document has been prepared in order to presents an overview of the Industrial Training Program of the

NDT Electrical Engineering of the Institute of Technology University of Moratuwa, that experienced by me.

It gives extensive details of the training experiences as well as the information about the training organization.

I had my second six months (18.09.2013 – 18.03.2014) of my first six month training program at Ceylon

Germany railway technical training center (CGR).

This report gives an overview of my training experiences and observations at the training period. It covers the

company background and includes information relevant to construction work to which I was exposed.

To get the full use of this report reader should has to read it in orderly manner. I have presented the report in

structured manner Thus for a person, who has an interest on specific area he can easily and understand. The

first chapter presents an overall view of the training organization. Second chapter gives the project details. In

the chapters following I have presented my training experience classified according to area of work covered in

the training. The final chapter is where I have stated my conclusion regarding the In-plant tainting as a whole.

The most important thing realized during this training period is, the theoretical knowledge is not the only

guidance to be a leading character in industry. Having sound knowledge in both theoretical and practical

aspects of the Electrical Engineering is the best way to develop myself as a professional engineer.

This is my second major report. It may contain any misinterpretation of details. Finally kindly I requested your

responses.

Thank you.

I.M ihsan

10/IT/EEI/119

Institute of Technology

University of Moratuwa.

ACKNOWLEDGEMENT

I would like to express my sincere gratitude to my internal supervisor, Mr.Ranjan Perera Lecturer Of Industrial

Training, Institute of technology University of Moratuwa for his excellent advice, constructive criticism and

suggestions provided me to complete the training.

I also express my gratitude to the lecture panel of the Division Of Electrical Engineering, ITUM. As well as, it

should be expressed my special thanks to the Chairman, National Apprentice and Industrial Training Authority

(NAITA) for organizing and supervising every aspects of my training.

I wish to acknowledge my deep gratitude to Mr. A.D wickramasinha, training operational manager, for his

valuable advices, suggestions and encouragement, to all foramens and supervisors.

The unreserved support and understanding of my beloved parents, brothers, sisters and my friends ensured

that I had a stable environment in which I can focus on my training.

I.M ihsan

10/IT/EE/119

Institute of Technology

University of Moratuwa.

Contains

Chapters page no

Chapter 01

Introduction of Ceylon Germany technical training center

Address

Vision

Mission

History of CGR

Organization chart

Chapter 02

Safety of workshops

First adi

Chapter 03 – workshop no 30

Workshop 30 introduction

Types and parts of batteries

Preparing of distilled water

Preparing battery acid solutions

Battery tests

Battery maintenance

Carriage wiring

Air condition wiring

Tinkering

Chapter 04 workshop no 35

Workshop 35 introduction

Starting motors

Parts of motors

Repairing of motors

Test

Repair and replacement

Schedule of services of motors

Small generators

Electronic devices

A.V.R

Winding and re windings

Chapter 05

Workshop no 35 introduction

A/C generator and motor

Rotor repairing

Stator repairing

Common problems

Armature balancing

Insulating coils

Chapter 01

Introduction of CGR ratmalana

The Ceylon railway, which was originally intended to bring the products of plantation in the center province to

the sea port of Colombo for shipment overseas and to transport machinery, fertilizers and other goods from

Colombo to the plantation area, has grown into a general major transport industry in the island covering all

populous districts by a network of railroads. Today fifty five percent of tea products in Ceylon is carried by rail

but the revenue derived from the transport of the commodity is 2.9 percent. Only of the gross receipts from all

sources, the railway has to cater to other needs of transport to earn balance 97.1 percent to revenue. The

subsequence of traffic has been in two major directions, viz,

The suburban traffic to and from the city of Colombo

The long distance passenger traffic and transport of fool, agriculture and other products.

There are three types of departments In the CGR

Civil engineering department

The civil engineering department of the railway during the last fifty years has carried out a number of major

products, which may be grouped in to two periods, viz, the per-independence period and the post-

independence period

Mechanical engineering department

In the year 1933 the workshop were transferred from mardana to ratmalana. The total area of the workshop

77acres out of which 12.6 acres are covered the chief mechanical engineer’s head office is a two storied

building.

The workshops are divided into 4 main groups namely

Locomotive group

Carriage and wagon group

Production group

Electrical group

Electrical group

The section on charge of five electrical engineers, fifteen electrical foremen, who are responsible for electrical

plant and ancillary gear in the railway. Generation of electricity is also available by using diesel generators in

when electricity is not available from local authorities.

Repairs of all electrical machinery, switchgear, etc.. is attended to at ratmalana.

Address

Srilanka Germany railway technical training center

Ratmalana

Map

Vision

To provide technical training conforming to international stranded in order to produce competent and skilled

man power required to maintain timely operated efficient steady and reliable passenger and good train series.

Mission

To become the training institute with the highest level of acceptance in srilanka in order to produce skilled

craftsman having national vocational skill level who are capable to go forward with a new technical

developments to railway and srilanka.

Organization chart

The organizational structure is prepared to show the levels the workers and officers, in a company

management the organizational structure is an important one, each officers can understand their

work and there power in the organization And while a worker reporting to the higher level by

following the structure, it will easy to solve problems, take decisions and passing informations.

CHIEF MECHANICAL ENGINEER (CME) SUB DEPARTMENTS

GTMGMA

GMO

Main mechanical engineer sub department

Main way & works engineering sub department

Main motive power sub department

Signal & telecommunication sub department

Srilankan railway superintendent

Transportation superintendent

Sales manager

Chief accountant of railway

Commercial superintendent

Srilanka German railway technical training center

GMR

Srilanka railway force superintendent

CHIEF MECHANICALENGINEER

DEEPUTY MECHANICAL ENGINEER

CHIEF ELECTRICAL ENGINEER

MEC-mechanical engineer of carriage

MES-mechanical engineer of special project

MEF-mechanical engineer of foundry

MEP-mechanical engineer of production

MEL-mechanical engineer of locomotive

MED-mechanical engineer of drawing

Chapter 02Safety of workshopIn this workshop mainly there are many chances to happen fire accident, lubrication oil and grease are spreading on the workshop surface there are so many chances to fire accidents and other accidents.And in the workshop the workers deal with high voltage and have machinery. So the safety rules must to fallow when working. But actually the workers are not wear the safety wears and never fallow the safety rules. But we can see the different types of fire cylinders everywhere. The details of fire the fire cylinders are on the table.

STORE KEEPER

TECHINICAL OFFICER

BUILDING DEPARTMENT FOREMAN

RAILING BUS PROJECT

ELECTRICAL ENGINEER OF TRACTION

ELECTRICAL ENGINEER OF POWER

ELECTRICAL ENGNEER OF CARRIAGE

MEC MES MEF MEP MEU MEDMEL(E)

FOREMAN

SURPERVISOR TRAINEESTIME KEEPER CLARK

MEL (P)MEL (H)

1ST CLASS TECHNICIAN

2ND CLASS TECHNICIAN

LABOURS

3RD CLASS TECHNICIAN

fire cylinders and usages

Color Type Solids Flammable liquids

Flammable gasses

Electric fire

Cooking oil & fats

red water × × × ×yellow foam × ×blue Dry powder ×black CO2 × ×

Fire brigadeThe major chance for fire accidents so there is a fire brigade is available and they have a fire brigade van for the expectation of accident at any working time. And number trained firemen are working in the fire brigade.

First aid boxIn every workshop there are two first aid boxes available. When happen any accident we can use those medicines. And the medicines are renewing every month, but there is no trained medical officer in each workshop

Medical centerThere is a medical center issue free medicine to workers if they are in ill while they work. At any time there is a medical doctor available to treat the workers when accidents happen. If the injury is major one, they send to general hospital by the workshop ambulance. The ambulance services also given to the workers as free.

Chapter 03 (workshop no 30)Introduction of workshop no 30This is the battery workshop that doing battery repairing, charging, battery testing air condition wiring, tinkering and battery installation, there are two foreman, three supervisors and thirty of workers are working in the workshop, the whole workers of workshop are divided as into three groups Battery groupTinkering groupA/C wiring group

Types and parts of batteries The batteries are mainly classified as into three categories, they arePrimary cells or non re chargeable batteries

Secondary cells or re chargeable batteriesBatteries by applications

Primary cells The primary cell is the very simple mechanism of a battery. These batteries are not re chargeable so after finished the saved energy of the batteries; this must to replace or repair to reuse. So this type of battery usage is becoming rare in industries. The output accuracy of the battery is very good. The tolerance of the primary cell is ±0.2V. Because of this only one reason this type of batteries are still used in industries. Examples of primary cellsAlkaline battery, aluminum ion battery, aluminum air battery, chromic acid cell, dry cell

But in train the alkaline cell was only used.

Secondary cellsThis type of cells are mainly using in industries because of law cost, ease of maintenance and can charge directly from utility power supply. The size of the batteries is small and the variable output batteries are available in market. So the usage in the industries is become large.

Examples of secondary batteriesFuel cell, lead acid battery, nickel cadmium battery, lithium ion and lithium air batteries. Molten salt battery

But the lead acid battery, lithium ion battery and nickel cadmium battery were only used to repair.

Batteries by applicationsThis a type of classification that the grouped according of the usage.ExamplesBackup battery, battery pack, car battery, button cell, bio battery

In CGR the car battery was taken under repair.

The batteries which are under taken for repair in CGR.

Alkaline batteryAlkaline batteries are a type of primary batteries dependent upon the reaction between zinc and manganese dioxide (Zn/MnO2). A rechargeable alkaline battery allows reuse of specially designed cells.

Overall reaction:Zn(s) + 2MnO2(s) ZnO(s) + Mn2O3(s) [e° = 1.43 V]

Voltage

The nominal voltage of a fresh alkaline cell is 1.5 V. Multiple voltages may be achieved with series of cells. The effective zero-load voltage of a non discharged alkaline battery varies from 1.50 to 1.65 V, depending on the purity of the manganese dioxide used and the contents of zinc oxide in the electrolyte. The average voltage under load depends on level of discharge and the amount of current being drawn, varying from 1.1 to 1.3 V. The fully discharged cell has a remaining voltage in the range of 0.8 to 1.0 V.

Current

The amount of current an alkaline battery can deliver is roughly proportional to its physical size. This is a result of decreasing internal resistance as the internal surface area of the cell increases. A general rule of thumb is that an AA alkaline battery can deliver 700 mA without any significant heating. Larger cells, such as C and D cells, can deliver more current. Applications requiring currents of several amperes, such as powerful flashlights and portable stereos, will require D-sized cells to handle the increased load.

Lead acid batteryDespite having a very low energy-to weight ratio and a low energy-to-volume ratio, its ability to supply high surge currents means that the cells have a relatively large power-to-weight ratio. These features, along with their low cost, makes it attractive for use in motor vehicles to provide the high current required by automobile starter motors.

The total chemical reaction can be written asPb(s) + PbO2(s) + 2H2SO4(aq) → 2PbSO4(s) + 2H2O(l)

These are general voltage ranges per cell

Open-circuit at full charge: 2.10 VOpen-circuit at full discharge: 1.95 VLoaded at full discharge: 1.75 VContinuous-preservation Charging: 2.23 V for gelled electrolyte; 2.25 V for AGM and 2.32 V for flooded cells

All voltages are at 20 °C (68 °F), and must (for a 6 cell battery) be adjusted by −0.0235 V/°C fortemperature changes.

Float voltage recommendations vary among manufacturers.

Precise float voltage (±0.05 V) is critical to longevity; insufficient voltage is almost as

Detrimental as excessive voltage typical (daily) charging: 2.37–2.4 V

Equalization charging (for flooded lead acids): 2.5 V for no more than 2 hours, 12 minutes, and 18Seconds. Battery temperature must be absolutely monitored.

Gassing threshold: 2.4 V

Vehicle batteryElectric vehicle batteries differ from starting, lighting, and ignition (SLI) batteries because they are designed to give power over sustained periods of time. Deep cycle batteries are used instead of SLI batteries for these applications. Traction batteries must be designed with a high ampere-hour capacity. Batteries for electric vehicles are characterized by their relatively high power-to-weight ratio, energy to weight ratio and energy density; smaller, lighter batteries reduce the weight of the vehicle and improve its performance. Compared to liquid fuels, most current battery technologies

have much lower specific energy; and this often impacts the maximum all-electric range of the vehicles.

A vehicle battery can be a Led acid battery, nickel metal hydride battery or a lithium ion battery

Parts of a battery (Ni-Fe storage battery)

Preparing distilled water and battery acid solution

Prepare distilled water to make the acid solution. The sulfuric acid of 35% and the distilled water of 65 % are mixed and allowed to cool. To produce the distilled water, a boiler was used. Then the water was used to mixed with the pure sulfuric acid. This was a very danger process the concentration sulfuric acid is a dangerous one, it can burn the skin, so we have to fallow the safety first.

boiler

The battery acid dilution cylinder

Battery tests The battery was tested at three times when after repaired, charging and discharging, at this time the battery have to have some specific characteristics. After repair the battery that means after filled with the battery acid, the battery solution was checked with a hydro meter. The density of solution and the concentration of sulfuric acid were being more. So the hydro meter will read a high value.

Charging test was did when the batteries were on charge, while charging the batteries terminal voltage was varying with the time, after full charged the terminal voltage was became to around 1.5V ±0.1.

The discharging test was did when discharge the batteries, to discharge the batteries a dis charger was used to discharge; the discharger has a nichrome coil which can convert the battery power into heat. When discharge batteries they were heated and ant they take different times to fully discharge. The temperature was noted down every hour and the total discharge time and the density of the battery acid solution density were noted down after fully discharge

Battery maintenance

The battery case are using as the very first starting energy source in the automobiles (train). So the batteries must to maintain in a proper way, so the every battery manufactures are release a maintenance schedule with their products, the user must to follow the instructions to get high efficiency. The common maintenance schedule is given bellow.

Maintain the electrolyte level in the range of lower – upper level only. If it is bellow that range, top up only with demineralized water. Do not use sulfuric acid

Keep the battery practically the venting of any dirt.

Check cables and, clamps, fastener, and case for obvious damages or loose connections.

Clean terminals and connectors as necessary.

General precaution

Never let your battery be punched by any sharp edges.Keep battery away any sparks or flame.Charge your battery in well-ventilated area.

A given battery instruction of operating manual

For a new charged battery, fill all cells with sulfuric acid of 1.260 – 1.280. in sulfuric gravity until reach the upper level, plug all vent holes with the provided vent plugs the clean battery top cover and terminals. Disconnect the all battery, ground terminal first, (usually negative terminals) then followed by the other terminals. Never do this in reversed order. Please check cables and clamps. Ensure it is rust free.Properly put and fasten the new battery on the car battery component. Tightly connect the terminals in reversed order with the disconnection order above. Cover all terminals with grease from corrosion prevention. Then the battery is ready to use.

Carriage wiring

The carriage wiring was mainly divided as in to two parts

Engine room control board wirings

Train box wiring

The engine board control board was fed from both battery and power generator. But the other train boxes were power fed from the lightning generator.

The train engine box 78 cells of batteries each of them have 1.5V terminal voltage. Those batteries are used when starting to give an instantaneous power to start the engine and to energized the engine box controlled equipment when the engine is off until the engine start.

To wire the lights and fans in the box, 1mm2×0.44’’/cu/pvc cables were used to terminate and 1mm2/cu/pvc cables were used to wire the engine box control board devices.

The battery was connected to starting motor. The starting motor is the starter of the engine. The starting motor has to energize for an instantaneous time then the power feed will start by the power generator. The power generator is operating by the train engine. 25mm2/cu/pvc cables were used to connect the starting motor and batteries.

Air condition wiringThere are only one air conditioned box in some trains. The air condition boxes there were two air conditions were fixed in each boxes. they were fed from power generators. 25mm2/cu/pvc/pvc cable was used to wire the air conditions. The air conditions control switch was fixed on the engine control board.

Tinkering Tinkering train boxes also coming under this workshop, the body of the train was polished and painted, but those works were supervised by a mechanical supervisor. After complete all wiring and repairing, the tinkering work will start by the tinkering group. The tinkering group was help to lay the wire in the train box and they help to hide the cables on the roof of the train.

Chapter 4 (workshop no 35 – electronic control, DC electrical machine and rewinding)

Introduction of the workshop no 35

This the workshop which is deal with dc electrical machines and electronic control devices. There are three major areas in this workshop. They are

DC motor repair section

The DC motors mean mainly the starting motors were repaired and serviced in the workshop. The schedule services of motors are maintained here. Every type of motors has got a different period of schedule services. After the period of the schedule time the motor will take for services.

Rewinding section

Re winding of the starting motors and all other motors were done in this workshop, if the winding burn or short circuited or other problems happened the motor will rewind to solve those types of problems.

Automatic voltage regulator designing section

This is an electronic part which is done in this workshop, the AVR of a train repaired and serviced in the workshop.

DC motors

There are veriable size of DC motors. Mainly the DC series motors are using as starting motors in automobiles (train). When start the vehicle the starting motor use to give the starting torque to the engine. So the staarting motor works for a instantinous time.the motors are feeding by the batteries of the vehicle. Some different types of starting motor has got permanent magnet to produce the magnetic field. And some large size motors has got cooling fane. The fans are directly coupled with the motor shaft.

The hole system are installed into a iron housing and the field windings are fixed on the inner surface of the housing and the rotarry part are fixed on bearing.

Repairing and servicies of dc motors

When start the repairing the fault of the motor have to find first. There are some common problames, normaly in a motor, those faults are happening

Fault Resons of faults solutions

Burned windings

Rapid using, over current, cooling failures or long time usage

Rewind the coils or some times (rarely), use a joint peace to to connect the both broken ends of the cupper string.the rewing is a huge repairing, so it will charge more, so the user must to fallow the user gide and maintenance instructions.

Break brushes or corrotions

Long time usage, un balanced armature, or smoothless commutator

When the fault happen the brushes must to replace to solve the problame, if the motor has unbalanced armature or smoothless commutator, the brushes will get break till the problams solve. So we have to balance the armature or smooth the surface of the commutator first.

Bearing failure Low maintanance, unbalanced armature, over load

Mainly the bearing failure is happening because of law maintanance. If dry grease in the bearing the bearing will get fail, once the bearing get failure, it must to change, otherwice motor will be noicey and there are chance to burn coil. The broken bearing is not a big issue but it will cause so many problams, so the bearings must to immediately, the user can find the failure form sound changes of the motor.

Unbalance armature

Attrition or along time usage, cooling failure

While using the motor along time, the armature get unbalance. When the armature is unbalnce, the motor vibration will more, and noice of the motor also get increase.

Schedule of servicies

Thechhedule of servicies will be prepaired according to the size, usage and environment of usage of a motor, some large size of motors has a time counter to calculate the running time, the productor release a common shedule chart with ther product to help the user. The shedule must to fallow to get

a good performance of theat motor, some time the maintanance shedule of a motor can be difference to same type motor.

According to the maintanance shedule the motors will taken under the servicies. Some of number of motors will take under servicies before the shedule time but most of them will taen for servicies after finish the shedule time.

Cleaning, painting, tinkering, and graesing works only do when the motor is faultless, if the motor has any fault, they will solve first before servicies.

While servicies a motor

Greasing

the grease can dry in the bearings and other moving parts of the motor. So that must to chack when service a motor, if the lubrication become dry then the motor bearing will break, will get got quckly and finaly there is a chance to burnthe coil.

Check the brushes

mostlt brushes failure filure is happening in motor, if there is a brushes fault in a motor, there will be create sparks.

Check the windings

there is a rare of chance to break the winding of a motor, (armature or field windings), so they also checked when under taken a motor.

Check the bearings

the bering failure is a common problam in the motor repairing. So they also checked when repairing. When over load condition work is the main reason to break the bearing.

Small generators als taken under repair, the motors was used in workshop, they were single phase generators.

A.V.R (auto voltage regulators)

The auto voltage regulators were repaired in this workshop. This is deal with of some power electronic devices and semiconductors. The AVRs are used to contro the train automaticaly, some perameters can display to the driver or the operator to correct manually, and some faults are controled automaticaly by the cordings of the AVR.

Winding and rewinding

The motors and the generators are have got windings, the windings is a important componant of an electrical machine to produce a magnetic field or to produce a force. The windings are wounded in iron leminations,

Some time the winding are got burn, because of the followwing resons,

Rapid usings

Over load

Cooling failuers

Along time usage

Insulation failures

When they occer the winding will get burn, or loss conductivity. Then the motor will no be usefull untill repair. That mean re wind the coils.

When take a machine to rewind, we must to know the perameters of the paticular motor windings. Other wise we cant re wind. So the motor manufactors release the data sheet with there productors.

But in practicaly going to repair a electrical machine, (motor or generator). We didn’t issue the deta sheet of the motor, so when we rewind the motor winding, whe take the details from the burned winding that what we want. And start to rewind.

The perameters were taken from the burned winding

The coil coupper string diameter

Number of turns

Winding style (top to top or bottom to bottom)

The details must to fallow when rewind to keep the same charactristic of themotor.

The rewind order

Remove winding

Remove the burned winding carefully from the stator or the rotor slots. Measure the winding shape and the diameter of the coil string are the important perametesrs of a winding.

Make a former

The winding former is wooden block, this is a coil former, the new coil will wind on this former first according to the original shape and sutable demension. Every motor has got different shape coils, so when start to rewind we need to make a new former.

Clean and paint the stators and rotors

The stator and the rotors were cleaned with water vapors and put into a hot oven to dry. Then the iro hosing was painted with a specal paint. It was painted to protect from corrotins and dust the motor surface.

Re installed the motor

Coil removed stator

The new coil was inserted into the slots and the rotor was sentered by adjest the bearings, then commutatoe was electricaly connected. Then the housing closed. Then chached by using a multimeter. The possibility of working of the motor was confonmed and delevered to install in train.