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 engineers 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.































GTM
GMA
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 MECHANICAL ENGINEER (CME) SUB DEPARTMENTS



























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


CHIEF
MECHANICALENGINEER
DEEPUTY MECHANICAL
ENGINEER
CHIEF ELECTRICAL
ENGINEER
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 MED
MEL(
E)
FOREMAN
SURPERVISOR TRAINEES
TIME KEEPER
CLARK
MEL
(P)
MEL
(H)
1
ST
CLASS
TECHNICIAN
2
ND
CLASS
TECHNICIAN
LABOURS
3
RD
CLASS
TECHNICIAN
Chapter 02
Safety of workshop
In 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.


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 brigade
The 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 box
In 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 center
There 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 30
This 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 group
Tinkering group
A/C wiring group

Types and parts of batteries
The batteries are mainly classified as into three categories, they are
Primary cells or non re chargeable batteries
Secondary cells or re chargeable batteries
Batteries 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 cells
Alkaline battery, aluminum ion battery, aluminum air battery, chromic acid cell, dry cell

But in train the alkaline cell was only used.

Secondary cells
This 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 batteries
Fuel 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 applications
This a type of classification that the grouped according of the usage.
Examples
Backup 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 battery
Alkaline 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 battery
Despite 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 as
Pb(s) + PbO2(s) + 2H2SO4(aq) 2PbSO4(s) + 2H2O(l)

These are general voltage ranges per cell

Open-circuit at full charge: 2.10 V
Open-circuit at full discharge: 1.95 V
Loaded at full discharge: 1.75 V
Continuous-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 for
temperature 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: 2.372.4 V

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

Gassing threshold: 2.4 V





Vehicle battery
Electric 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, 1mm
2
0.44/cu/pvc cables were used to terminate and
1mm
2
/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. 25mm
2
/cu/pvc cables were used to
connect the starting motor and batteries.

Air condition wiring
There 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.