dlw training report, varanasi

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ISO – 9001:14001 Certified

TRAINING REPORT

D. L. W. (Diesel Locomotive Works)

SUBMITTED BYSUBMITTED BYSUBMITTED BYSUBMITTED BY

VIVEKANAND PANDEYVIVEKANAND PANDEYVIVEKANAND PANDEYVIVEKANAND PANDEY

B.TECH 3B.TECH 3B.TECH 3B.TECH 3rd YEARYEARYEARYEAR

MECHANICAL ENGINEERINGMECHANICAL ENGINEERINGMECHANICAL ENGINEERINGMECHANICAL ENGINEERING

TABLE OF CONTENTS:

1. Acknowledgment

2. Preface

3. Introduction of D.L.W.

4. Brief History

5. Product

• EMD

• WDP4

6. Manufacturing Process

• Engine Division

• Vehicle Division

• Block Division

6. Workshops

• Heavy Weld Shop

• Light Machine Shop

• Engine Testing

• T.M.S.

7. Organizational Strength

8. Conclusion

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I would sincerely like to thank the employees & the officers

of DLW, Varanasi for their help & support during the

vocational training. Despite their busy schedules, they

took time out for us & explained to us the various aspects

of the working of the plant, from the production shops.

I expressed my thanks to the lecturer Mr. D.P. Singh &

HOD of department, Dr. B.K. Singh for extending his

support.

I would also thank my institution & my faculty members

without whom this report would have been a distant reality.

I also extend my heartfelt thanks to my family & well

wishers.

PREFACE

The objectives of the practical training are to learn

something about industries practically & to be

familiar with the working style of technical person

to adjust simply according to the industrial

environment.

It rightly said practically life is far away from

theoretical one. We learn in class room can give

the practical exposure or real life experience no

doubt they help in improving the personality of the

student, but the practical exposure in the field will

help the student in long run of life & will be able to

implement the theoretical knowledge.

As a part of academic syllabus of four year degree

course in Mechanical Engineering .Every student

is required to undergo a practical training.

I am student of Third year mechanical & this

report is written on the basis of practical

knowledge acquired by me during the period of

practical training taken at Diesel Locomotive

Work, Varanasi

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INTRODUCTION

Diesel Locomotive Works is production unit under

the ministry of railway. This was setup in

collaboration with American locomotive company

(ALCO) USA in 1961 & the first locomotive was

rolled out in 1964. This unit products diesel

electronic locomotive & DG sets for Indian railways

& other customers in India Abroad.

Subsequently a contract for transfer of technology

of 4000HP Microprocessor Controlled AC/AC

Freight (GT 46 MAC) / passenger (GT 46 PAC)

locomotive & family of 710 engines has been

signed with electromotive division of GM of USA

for mfg in DLW is the only mfg of Diesel Electric

locomotive with both ALCO & GM technologies in

the world.

BRIEF HISTORY

The Diesel Locomotive Works (DLW) in Varanasi India

is a production unit owned by Indian Railways, for which

it manufactures diesel-electric locomotives & spare

parts.

August 1961 DLW set as a green field project in technical collaboration with ALCO, USA for manufacture of Diesel Electro Locomotive.

January 1964 First Locomotive rolled out & dedicated to the Nation.

January 1976 Entered Export market, first locomotive exported to Tanzania.

December 1977 First Diesel Generating Set commissioned

October 1995 The Transfer of technology agreement was signed.

March 2002 The first indigenous EMD WDG4 freight locos manufacturing.

November 2002 3600 HP Engine manufactured

March 2003 The first indigenous passenger version of EMD loco WDG4 manufactured

September 2003 Development of 16 cylinder 330 HP power upgraded DLW engine, WDM3D locomotive

November 2006 DLW manufactured first DG4 locomotive equipped with IGBT based convertor

March 2007 First WDP4 locomotive equipped with IGBT based convertor.

April 2007 DLW has successfully switched over to use of microprocessor based control system on all its locomotives.

March 2009 257 locomotives manufactured in 2008-2009, highest ever locomotive production.

November 2009 5690 locomotives up to 30th Nov 2009(including 348 EMD locos).

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Types of LOCOMOTIVES PRODUCTION at DLW

� The first letter (gauge) 1. W- Indian broad gauge( The “W” stands for wide Gauge-5ft)

2. Y- meter gauge( The “Y” stands for Yard guage-3ft)

3. Z- narrow gauge(2ft 6 inch)

4. N- narrow gauge(2ft)

� The second latter (motive power)

1. D- Diesel

2. C- DC electric (can run under DC traction only)

3. A- AC electric (can run under AC traction only)

4. CA-Both DC & AC (can run under both AC & DC tractions)

5. B- Battery electric locomotive (rare) � The third letter (job type) 1. G- goods

2. P- passenger

3. M-mixed; both goods & passenger

4. S-Used for shunting (also known as switching engines or switchers in

United States & some other countries)

5. U-Electric multiple units (used as commuters in city suburbs)

6. R-Railcars

Ex: - “WDM3A”:

“W”- broad gauge

“D”- diesel motive

“M”- suitable for mixed service

“3A”- The locomotive’s power is 3100HP

Or,

“WAP5”:

“W”- broad gauge

“A”- AC electric traction motive power

“P”- suitable for passenger

“5”- denote that this locomotive is chronologically the 5th electric locomotive model

Used by the railway for passenger service.

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DIESEL TRACTION ASSEMBLY AT DLW

• EMD � WDG4- 4000 HP GOODS LOCOMOTIVE

(WDG4 LOCOMOTIVE) (TRACTION EFFORT & POWER CHART)

Diesel Engine Transmission

• 16 cylinder 710G3B, 2 stroke, turbocharger. After cooled.

• Fuel Efficient Engine • Injection System? direct Unit Injector • Governor? Woodward • Compression Ratio 16:1 • Lube Oil Sump Capacity 950Lts

• Electrical Ac-Ac

• 6 Traction motor (3in parallel per bogie)

• Suspension? Axle hung/taper roller bearing.

• Gear Ratio 90:17

Truck Brakes

• High adhesion HTSC (High Tensile Steel Cast)truck of bogie

• Adhesion 0.42

• Electronic Air Brake System(KNORR-NYAB-Computer Controlled Braking)

• Air, hand, dynamic brake • Pure air brake

General Characteristic

• Installed Power • Axle Load • Gauge • Wheel arrangement • Wheel diameter • Height • Width • Overall Length(Over Buffer Beam) • Weight • Max tractive effort • Maximum speed • Fuel tank capacity • Locomotive control

• 4000HP • 21 T • 1676mm • Co-Co • 1092mm • 4201mm • 3127mm • 19964mm • 126 T • 54 T • 100Kmph • 6000Lts • EM 2000 with SBIAS-16 Traction

Control

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� WDP4- 4000HP PASSENGER LOCOMOTIVE

Diesel Engine Transmission

• 16 Cylinder 710 G3B, 2 stroke, turbocharged � after cooled

• Fuel Efficient Engine

• Injection System � Direct Unit Injector

• Governor � Woodward

• Compression Ratio- 16:1

• Lube Oil Sump Capacity � 1073Lts

• Electrical AC-AC

• 4 Traction motor ( 3 in parallel per bogie)

• Suspension � Axle hung / taper roller bearing

• Gear Ratio � 77:17

Truck Brakes

• High adhesion HTSC ( High Tensile Steel Cast) truck or bogie

• Adhesion � 0.42

• Electronic Air Brake System ( KNORR-NYAB-Computer Controlled Braking)

• Air , hand , dynamic brake with fully blended with automatic brakes

• Pure air brake

General Characteristic

• Installed Power

• Axle Load

• Gauge

• Wheel arrangement

• Wheel diameter

• Height

• Width

• Overall Length (Over Buffer Beam)

• Weight

• Max tractive effort

• Maximum speed

• Fuel tank capacity

• Locomotive Control

• 4000 HP

• 19.5 T

• 1676 mm

• A-A-I I-A-A

• 1092 mm

• 4201mm

• 3127 mm

• 19964 mm

• 117 T

• 27 T

• 160 Kmph

• 4000 lts

• EM 2000 with SIBAS-16 Traction Control

• ALCO:- � 1350 HP CAPE GAUGE LOCOMOTIVE VDM4

TECHNICAL INFORMATION

1350 HP Locomotive having fabricated cape gauge Co-Co bogie. hese locomotives have been supplied to Angola and Sudan.

Wheel Arrangement Co – Co

Track Gauge 1067 mm Cape gauge

Weight 72 t

Overall Length 15600 mm

Wheel Diameter 921 mm

Gear Ratio 18: 93

Maximum Speed 90 Kmph

Diesel Engine Type: ALCO 251 D 6Cyl. In line.

HP 1350

Transmission Electrical AC/DC

Brake 28LAV-1 system

Loco Air, dynamic, parking

Train Air & Vacuum

Fuel Tank Capacity 3000Litres

� 2300 HP CAPE GAUGE LOCOMOTIVE


2300HP Main Line Locomotive, having fabricated cape gauge Co-Co bogies. These are provided with

two drivers cabs, one at each end. These locomotives have been supplied to Angola and Sudan.

Wheel Arrangement Co-Co

Track Gauge 1067 mm Cape Gauge

Weight 102 t


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Gear Ratio 18 : 93

Maximum Speed 100Kmph

Diesel Engine Type: ALCO 251-B 12Cyl. V- Engine

HP 2300


Brake IRAB-1

Loco Air, Dynamic, parking

Train Air


� 2300 HP METER GAUGE LOCOMOTIVE


2300HP Main Line Locomotive, having fabricated meter gauge Co-Co bogies. These are provided with two drivers cabs, one at each end. These locos have been supplied to Malaysia, Senegal and Mali.


Track Gauge 1000 mm Meter Gauge

Weight 102 t



Gear Ratio 18 : 93


Diesel Engine Type: ALCO 251-B 12Cyl. V- Engine

HP 2300


Brake IRAB-1

Loco Air, Dynamic, parking

Train Air


� 3000 HP CAPE GAUGE LOCOMOTIVE

TECHNICAL INFORMATION (Provisional Specifications)

3000HP Micro Processor Controlled, Main Line, Cape Gauge Locomotive with improved Cab, under development for Mozambique Railway


Track Gauge 1067 mm Cape Gauge

Weight 114 t



Gear Ratio 19 : 92


Diesel Engine Type: ALCO 251-C 16Cyl. V- Engine

HP 3000


Brake IRAB-1

Loco Air, Dynamic

Train Air


� 1350 HP METER GAUGE LOCOMOTIVE YDM4


1350HP Locomotive having cast / fabricated meter Gauge Co-Co bogie . Such locomotives have been supplied to Vietnam and Myanmar.

Wheel Arrangement Co - Co

Track Gauge 1000 mm

Weight 72 t



Gear Ratio 18: 93


Diesel Engine ALCO 251 D 6Cyl. In line.

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HP 1350


Brake IRAB � 1 system / 28LAV-1

Loco Air, dynamic, parking

Train Air / Dual (Air and Vacuum)


� BROAD GAUGE MAIN LINE FREIGHT LOCOMOTIVE WDG 3A


Diesel Electric main line, heavy duty goods service locomotive, with 16 cylinder ALCO engine and AC/DC traction with micro processor controls


Track Gauge 1676 mm

Weight 123 t

Length over Buffers 19132 mm


Gear Ratio 18 : 74

Min radius of Curvature 117 m


Diesel Engine Type : 251 B,16Cyl.- V

HP 3100

Brake IRAB-1

Loco Air, Dynamic

Train Air

Fuel Tank Capacity 6000litres

� BROAD GAUGE MAIN LINE MIXED SERVICE LOCOMOTIVE WDM 3D


Diesel Electric Locomotive with micro processor control suitable for main line mixed Service train operation.


Track Gauge 1676 mm

Weight 117 t

Max. Axle Load 19.5 t

Length over Buffer 18650 mm


Gear Ratio 18 : 65


Diesel Engine Type: 251 B-16Cyl. �V� type (uprated)

HP 3300 HP (standard UIC condition)

Transmission Electric AC / DC

Brake IRAB-1 system

Loco Air, Dynamic, Hand

Train Air


� BROAD GAUGE SHUNTING LOCOMOTIVE WDS 6AD


A heavy duty shunting Diesel Electric Locomotive for main line and branch line train

operation. This locomotive is very popular with Steel Plants and Port Trusts.


Track Gauge 1676 mm

Weight 113 t

Length over Buffer 17370 mm


Gear Ratio 74 : 18


Diesel Engine Type: 251 D-6Cyl. in-line

HP 1350 / 1120 HP (std.)

Transmission Electric AC / DC

Brake IRAB-1

Loco Air

Train Air


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MANUFACTURING PROCESS

• ENGINE DIVISION

COMPONENT MACHINING

Over 2000 components are manufactured in-house at DLW. These include ALCO turbo

superchargers, lubricating oil pumps, cam shafts, cylinder heads, laser hardened cylinder

liners, connecting rods and various gears. Our well-equipped Machine Shops have

dedicated lines for operations like turning, milling, gear hobbing, drilling, grinding and

planning etc.

In addition, DLW is equipped with a variety of special purpose machines and a large number

of state-of-the-art CNC machines to ensure quality and precision. Associated manufacturing

process like heat treatment and induction hardening are also carried out in-house.

A new eco friendly laser hardening machine has been setup which is designed to laser

harden the inner bore of engine cylinder liner and this feature advantages such as low

running cost, state of the art controls to provide reliable and versatile laser power for ultimate

quality requirements.

Engine Assembly & Testing

Pre-inspected engine block, crankshaft, cylinder liners, pistons, connecting rods, cylinder

heads, exhaust manifold, turbo supercharger and all related piping are used in assembly of

engine. Electrical machines like traction alternator, auxiliary generator and exiter are

thereafter coupled on the engine.

The complete power packs with electrics are tested on computerized Engine. Test Bed to

verify prescribed horsepower output. Vital parameters of engine health are checked to

assure the quality of product. Only after the engine parameters are found perfect the power

pack are cleared for application on locomotives.

• LOCO DIVISION Component Fabrication

Precision cutting and forming of sheet metal is utilized for manufacture of

superstructures including drivers cab engine hoods, and compartments for housing

electrical equipment. All activities connected with pipes like pickling, bending,

cutting, forming and threading of pipes of various sizes are undertaken in

another well-equipped work area.

All electrical equipment is assembled in the fabricated control compartments and

driver's control stands are done in another work area.

Under frame Fabrication

Under frames are fabricated with due care to ensure designed weld strength. Requisite

camber to the under frame is provided during fabrication itself. Critical welds are tested

radio-graphically. Welder training and their technical competence are periodically reviewed.

High Horse Power (HHP) under frame is fabricated using heavy fixtures, petitioners to

ensure down hand welding.

Fixtures are used to ensure proper fitting of components and quality welding in

subsequent stages.

BOGIE MANUFACTURING

Special purpose machines are utilized for machining cast and fabricated bogie frames. Axle

and wheel disc machining is undertaken on sophisticated CNC machines. Inner diameter of

wheel discs are matched with the outer diameter of axles and assembled on wheel press.

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The complete truck (bogie), including bogie frames, wheels and axles, brake rigging and

traction motors are assembled which is ready for application to locomotive.

LOCOMOTIVE ASSEMBLY

Tested engines are received from Engine Division. Similarly under frames are

received from Loco frame shop and assembled trucks from Truck machine shop.

Superstructure compartments and contractor compartment are received from

respective manufacturing and assembly shops of Vehicle Division. Important

alignments like crank shaft deflection; compressor alignment and Eddy Current

clutch/radiator fan alignment are done during assembly stage.

Electrical control equipments are fitted and control cable harnessing is undertaken.

The complete locomotive is thus assembled before being sent onwards for final

testing and spray painting. All locomotive are rigorous tested as per laid down test

procedures before the locomotive is taken up for final painting and dispatch for

service.

• BLOCK DIVISION

Flame Cutting of Components

Steel plates of sizes up to 80 mm thickness are ultrasonically tested before being

precision cut by numerically controlled flame cutting machines, Plasma Cutting

Machine. Components are straightened and machined prior to fitting & tacking on

fixture designed specially for engine block fabrication to ensure close tolerance on

engine block.

Fabrication of Engine Block/ Crankcase

Components after flame cutting and various machining operations are fit and tack

welded before taking on rollovers. Heavy Argon-CO2 welding is done on these

rollovers. High quality of welding is done by qualified welders. Weld joints are

subjected to various tests like ultrasonic, X-rays, Visual etc. Down-hand welding is

ensured using specially designed positioners.

Fabrication of engine block is completed by submerged arc welding using semi-

automatic welding machines. Special fixtures are used for making down-hand

welding possible in inaccessible areas. Critical welds are subjected to radiographic

examination. All welders are periodically tested and re-qualified for the assigned.

After complete welding weldment is stress relieved and marking is done for

subsequent machining.

Portal Milling Machine

Engine block machining is done on Portal Milling Machine which is a 5 axis CNC

machine with SIEMENs 840-D state of art system control with dedicated tool

management system.

This machine performs milling, drilling, tapping and boring operations in single

setting. The machine accuracy of 10µ enables adhering to the tolerance required on

engine block.

Angular Boring Machine

Angular boring "V" boring is done of special purpose machine which is a special

purpose machine, which has two high precision angular boring bars on which

different boring inserts are mounted. The cutting inserts on boring bars to achieve

evenly distributed cutting load during boring operation. This contributes to accuracy

while machining.

Boring bars are mounted on high precision bearings which provide control on size

during angular boring. The machine is capable of boring and drilling to different

sizes.

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WORKSHOP

� HEAVY WELDING SHOP(HWS)

� LIGHT MAHINE SHOP(LMS)

� ENGINE TESTING(ET)

� TRUCK MACHINE SHOP(TMS)

This shop deals with the matching of various small component required for the power

pack unit such as, cam shaft, connecting rod, liners, gears levers, F.P. Support,

Piston pin, nuts & bolts bushes, various shafts etc.

� HEAVY WELDING SHOP(HWS)

This shop mainly deals with fabrication of the engine block and base (B.G & M.G)

Turbo support after cooler housing items. The engine block is structural member of

the diesel engine. It is composite weldment with heavy plates thickness varying from

16 mm to 75 mm & steel forgives conforming to specification is 2062.

The spine being the most highly stressed item as we can say spine of the cylinder

block is made out of one piece bitted 5” * 7” thickness conforming to be 1895.

1. DIFFERENT WELDING PROCESS USED IN HEAVYWELDING SHOP

(H.W.S.)-

• Electric arc welding.

• Gas welding

• Forging welding. Joining of two components by gas electric arc or forge of same or different material homogeneous and dense joint is called welding.

2. Blocks in DLW-HWS- a. ALCO (American Locomotive) block Power V Type 6 cylinder 2300hp Engine 12 cylinder 2600hp 45¶ alignment 16 cylinder 3300hp 45¶alignment b. GM (general Motor) block or EMD (Electromotive Division) block Power 16 cylinder 4000hp 20 cylinder 5000hp

3. ALCO components A. Saddle

No. of use width

Intermediate Saddle 07 4.5”

Center Saddle 01 6.75”

T Saddle 01 4.625”

B Foundation Plate (L & R)

Two ends free and generator end L and R

Foundation plates are decided by Generator. c. Spines D. Outside walls Width L 20mm R 20mm E. Middle deck Width L 40mm R 40mm F. Inside wall Width L 16mm R 16mm G. Top deck L R In spine welding root run takes place from 1, 3, 5, 7, 9 and then 2, 4, 6, 8.In root run, 4.5 to 5mm electrode is used for welding. After root welding 6.5mm electrode is used. X-ray quality joints are produced in ALCO.

4. Welding types in HWS a. Manual metal arc welding (MMAW) b. Gas metal arc welding (GMAV) c. Submerged welding ± shielding is provided by flux. On the basis of use - Internal submerge welding - External submerge welding CO2 and agro shield (Argon 82% and CO2 18%). CO2 creates shield and wt off the contact of flux from environment and prevent oxidation of metal,

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5. Tandem welding:- Used for heavy metal deposition. Use A.C. and D.C. current both for welding. DC arc lead AC arc transition welding process. Heat input is very low. Good penetration is obtained. It is one time welding process while in internal and external submerged welding the process can be repeated several times. 6. Stress relieving:- After complete block fabrication heat treatment is done. We put block into diesel furnace for 28hours.Temprature arises into diesel furnace. At rate 0f 50’per hour and reach upto 450’C and then rises at the rate of 30’c per hour upto 640’c. At 640’c block is kept in furnace for 10 hours and its temp. Reaches at range of 250-280’c.

Coating: - Electrode is coated by iron dust and other filler material. Coating is done for shielding of welding process. Type of coating: a. Low coating ± Deposition efficiency 110%. b. Medium coating - Deposition efficiency 110-129% c. Heavy coating - Deposition efficiency 129-140% d. Super heavy Coating - Deposition efficiency 140-220%. Deposition Efficiency:- It is defined as the ratio of amount of material included is weld to the amount of material supplied.

� Light Machine Shop (LMS)

About 240 spare parts required by DMW and Zonal Railways for locomotive maintenance including Camshafts, Cam & Split Gears, Bull Gears, Valve gear components, Equalizer

beams, Axles, Armature shafts, Gas inlet casings, etc. are manufactured in the Light Machine Shop. DMW was the first Production Unit of the Indian Railways to adopt NC-CNC machines

on a large scale.

The light machine shop divided into the following section:-

I. Econometric section II. Grinding section

III. Gear section

IV. Cam shaft section

V. A.T.I. section VI. Belching section

VII. Connecting rod section

VIII. Lathe section IX. Liners section

X. Drilling section XI. Milling section

Connecting rod section: In this section the connecting rod is made. All the machining operations of the

connecting rod. Completed here with the help of various types of machine. The connecting

rod has two parts; one is cap and other is rod. The material of the connecting rod is steep

forging. In B.G. 16 per loco and in M.G. 6 per loco.

Main dimensions

1. Crank bore (big bore) =6-411ǁ”to 6.421” 2. Piston pin bore (small bore) =3.998”to 3.999” 3. Distance between Two = 20.995” to 21.000” bare centre 4. Rod Thickness = 3.020” to 3.022” 5. Weight = 32 Kg 950 gram to 3 2 Kg gram.

6. Pressure Torque = 150 P.S.I

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1. Econometric section:- This section manufacturing various sizes etc. Machine provided: -Econometric machine, do-all machine, belt grinding machine (for

control shaft feed)

02. Gear- Section: - This section deals to making various gears impeller such as: camshaft gear, crank shaft gear,

extension shaft gear, impeller gear (follower& drive) and broaching Machine Provided:- (a) Gear hobbling machine

(b) Gear shaving machine

(c) V.T.L. machine

(d) Radial drilling machine (e) Broaching machine &

(F) Centre mill M/C

03. Grinding Section: - In this section the various small components are grinding as per required finishing after

machining operation and each components having grinding allowance (G.A.) main piston pin,

impeller and fuller and follower gear, pin valve guide, various studs. Cam roller, seat (V/C Q

‘X‘head) spider various bushes etc.

Machine provided (a) Cylindrical grinding machine

(b) Internal grinding machine

(c) Centre less grinding machine

(d) Thread rolling machine

(e) Universal grinding machine

(f) External grinding machine

04. Camshaft section

This section making cam shaft (both B.G. & M.G.) with completed machining operation by

various special type of machine. In B.G. 08 nos per loco and in M.G. 03 per loco.

Machine Provided

1. Centre mill machine

2. Auto lathe machine

3. Gun drill machine

4. External grinding machine

5. Lathe machine

6. Cam grinding machine

7. Radial drilling machine

8. Cam angle checking machine

9. Magna flux machine

Cam shaft length size (B.G.)

Cam shaft no. Do all size Milling size?

16 B731 73 39 29/32” 39.656” 74 37 1/8” 36.875” 75 39 3/8” 39.125” 76 47 11/32” 47.093” 77 43 3/32” 42.843” 78 37 1/8” 36.875” 79 47” 46.750” 80 38 17/32” 36.281”

Cam shaft length size (M.G.) Cam shaft no. Do all size Milling Size?

16B 95 33 3/8” 33.125” 96 32 7/8” 32.625” 97 41 13/32” 41.156”

Cam angle Air cam 7 angle 315.769” 315-46 Fuel cam 7 angle 327

Ex. Cam 7 angle 238.936 238-56

Air cam 8 angle 45.769 45-46

Fuel cam 8 angle 57

Ex. Cam 8 angle 328.936 328-56

05. Automatic Turret Lathe (A.T.L) Section:-

This section manufacturing various types of small components for Power pack engine such

as: Lock spring seat (V/L & X-Hd) spewing seat. Ball end, cup end ad

Screw (X-HD & V/L) cop screws L.A.S. retainer, spring lever, F.P. inlet, Porg Bkt. piston

pin liner sleeve, body outer ring spicier etc. machine provided.

1. M.T.L. (Bar type, chuck type) 2. U.T.L

The A.T.L. section is the vital section of this shop. Maximum small components are

manufacturing in the section

06. Benching Section:

In this section the benching operation of the entire component which are

manufacturing in the shop are done here. In the benching section. There hawing hand

cutter machine and belt grinding machine, with the half of these machine

bar removing from all the components.

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07. Cyl. Liner Section: In this section .cycle liner machine operation have done here by the various type of

m/cs. the material of the cyl. Liner is spe. Cast iron and the set the per loco is in B.G.

16 and in M.G. 6 cylinder Main Dimension:- 1. Length 21 15/16 + 1/64

2. Inside dia rough honing -9.010” 3. Inside dia finish honing – 9.015” 4. outside dia – 10.00” 5. Dia of groove– 10.749 to 10.750”

Machine provided:- 1. Shot blast machine.

2. Vertical boring machine 3. Auto lathe machine.

4. Honing machine. 5. Cylindrical grinding machine

08. Lathe section: This section deals various types tropical small components

are manufacturing. Centre lath machines or provided in this section. The components

are: brass sleeve, wear plate, valve guide, long stud, shaft etc.In drum type turret lathe

M/C manufacturing pin cam roller, cup end, bush washer etc.

09. DRILLING section:- In this section dials with various Types of drilling, reaming, counter bore

spot tracing and counter sinking operation done of various small components. The

components are, F.P. support, P.R. Lighter, X head, Valve Lever, Spring Lever, Brg,

Bracket, Pin, Ecc Lever, Upper housing etc.

MACHINE PROVIDED:- 1. Radial drilling Machine,

2. Gang drilling machine of multi spindle drilling machine

3. Drilling Machine

4. Electronic drilling machine.

10. MILLING MACHINE:- This section manufacturing various types of milling operation of the

components in types of milling machine. MACHINE PROVIDED:-

1. Vertical milling machine

2. Horizontal milling machine

3. Universal milling machine.

CAM -SHAFT OBJECTIVE: -

The Cam shaft is made replaceable section of heat treated precision machined alloy

steel with chromium. The Cams are formed internal with shaft and bearing and Cam

Surfaces andhardenedby high frequency induction.

Shaft is driven from the crank shaft through a forged steel heat treatedspan type gear

train of adjusted adequate diameter and face width. The push rod lifter having contact

with its cams through their rollers over the valves air inlet and exhaust gases. The

middle cross head lifted operates the injection to inject the fuel. In the generator end

of cam shaft a gear is coupled with which gives the motion to turbo generator which

generate the electricity for the governor of the engine. In the other end of the cam

shaft a carrier weight is linked after the cam shaft vibration dumper which is housed in

O.S. Trip assly and operate stripping of system. Through its plunger that is opened by

the centrifugal force of cam shaft rotation.

PROCEDURE: - Four shafts having no 77, 78 79 +80for right side ware leaned thoroughly. Passed the

dowel pins in holes of 0.499” Kept these shafts on leveled co- boars with the pilots.

The sequence of number male and female flanges must be like 77, 78,

79&80respectivesly .applied 18 no studs of y2 N.F. and fastened items with Elastic stop nuts 36 no. applied y2” plug on generator end. Similarly other four shafts having SL. no. 73, 74, 75, &76 for left side were assly. Material specification: - M.S., CR steel D.81602HR application of camshafts for the

different engines is as follows:-

M.G. 95, 96, +97

B.G. 73 74 75 &76, 77, 78, 79, & 80

L.S. R.S.

WDML: - 107, 108, &109/ L.S.,

104, 105, &106/ R.S. VIBRATION DAMPER ASSEMBLY.-

CRANK SHAFT (TYPE 251 B) OBJECTIVE:- The Vibration damper is fitted with crank shaft to prevent the vibration

of crank shaft when the engine starts the Crank shaft gets a sudden shock the

VibrationTrademark diminishes these shocks. In the same way when the engineStops

unexpectedly the crank shaft gets a heavy shock. So the get heavy shock.

So we gets reduced of these shocks we use the vibration damper asa safety device and

to increase the life of crank shaft.

Material:-- Outer ring steel 54190Intermediate ring steel 54190Spider cast iron 8054 PROCEDURE: -- Debarred the holes of outer ring and screw hole of 1 by2” Applied lye bolt in the threaded holds cleaned. Placed the outer ring plate on a round wooden piece of 6ǁ height from centre Bore side of it to downward. Place the intermediate ring on the outer plate dropped a

little oil on the top of the intermediate ring.

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� Engine Testing:- Engine test operation sequence: 1. Bare inspection under screen and fitting over screen. 2. Water circulation. 3. Lube oil filling and check deflection crankshaft. 4. Lube oil circulator. 5. Pre runs no load ± 3runs 5, 10, 30 minutes (400rpm). 6. Intermediate runs 12 runs of 30 minutes duration each from 400rpm to1000rpm.Load 68 to 2330bhp. 7. Check over speed trio of re-check three times. 8. Check brake in nozzles and set tapped clearance. 9. Inspection before first hour performance. 10. First hour performance on full load. 11. Base inspection. 12. Second hour performance on full load. 13. Attend defects of first hour performance. 14. Final base inspection. 15. Check engine deficiencies. 16. Engine clearance.

Lubricating oil testing � Lubrication is done for better performance of the engine parts.

� testing is done by checking the circulation of lubricant oil.

� for rotating parts checking is done by seeing the returning path of the oil i.e. checking not

only the forward path but also the returning path.

� RR40 is used as lubricating oil

Water testing Water acts as a coolant for moving part of the engine because constant

movement or rotation causes various parts to heat up and water working as

coolant cooled down the concerned part.

Load testing For load testing electrical load is provided to the engine. If there is any

abnormal sound then the engine is again tested for lubrication so that any flaw

which is there can be removed.

Engine assembly parts-

• Crank case

• Oil pan

• Power assembly(16 no)

• Crank shaft (1 no.)

• Cam shaft (RS & LS)

• Control shaft (RS & LS)

• Head frame (RS & LS)

• Turbo supercharger

• Alternator

• Injector

• Oil separator

• After cooler (R & L)

• After cooler duct (R & L)

• Woodward Governor

• Governor drive

• O.S.T. device

• Detector assembly

• Thermostatic valve

• Water pump (R & L)

• Main lube oil pump

• Scavenging lube oil pump

• Lube oil strainer

• Soak back pump

• Cranking motor (starting motor)

• Turbo lube oil filter

• Soak back filter

• Ring gear

• Flexible coupling

• Ring gear coupling

• Auxiliary drive

• O.S.T. shaft (R & L)

• Rocker arm (16 set)

• Fuel oil injector (16 no)

• Cylinder head assembly (16 no)

• Connecting rod (6 no)

• Governor booster pump

• Fuel oil manifold

• Fuel oil junction box 1. Valves

For a two-stroke engine, there may simply be an exhaust outlet and fuel inlet

instead of a valve system.

2. Exhaust systems

The exhaust system frequently contains devices to control pollution, both

chemical and noise pollution.

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3. Cooling systems

Combustion generates a great deal of heat, and some of these transfers to the

walls of the engine. Cooling systems usually employ air or liquid (usually water)

cooling.

4. Piston:

It is located in a cylinder and is made gas-tight by piston rings. Its purpose is to

transfer force from expanding gas in the cylinder to the crankshaft via a piston

rod and/or connecting rod. In two-stroke engines the piston also acts as a valve

by covering and uncovering ports in the cylinder wall.

5. Crank shaft: Most reciprocating internal combustion engines end upturning a shaft. This

means that the linear motion of a piston must be converted into rotation. This is

typically achieved by a crankshaft. 6. Starter systems: All internal combustion engines require some form of system to get them into

operation. Most piston engines use a starter motor powered by the same battery

as runs the rest of the electric systems.

7. Lubrication Systems: Internal combustions engines require lubrication in operation that moving parts

slide smoothly over each other. Insufficient lubrication subjects the parts of the

engine to metal-to-metal contact, friction, heat build-up etc.

8. Alternator Alternators generate electricity by the same principle as DC generators, namely,

when the magnetic field around a conductor changes, a current is induced in the

conductor according to faraday’s law of electromagnetic induction.

9. Governor a device used to measure and regulate the speed of an engine. The microcontroller based governor consists of a control unit mounted in the

drive cab and an actuator unit mounted on the engine. The governor controls the engine speed based on throttle handle position. Engine RPM is measured by an engine speed sensor mounted on the engine. Air pressure is measured through a pressure sensor mounted in air manifold,

and movement of fuel rack is limited as a function of this pressure so as to

prevent incomplete combustion, black smoke, excessive engine temperature,

fuel wastage etc.

10. Control unit features

• 16 bit microcontroller based design

• No need of regular maintenance.

• Effective control for complete combustion of fuel improves fuel efficiency

and reduces pollution.

• Continuous display of engine status parameters.

• Online fault diagnostics and fault message display.

11. THROTTLE It is the mechanism by which the flow of a fluid is managed by constriction

or obstruction. An engine's power can be increased or decreased by the restriction of inlet

gases. A throttle position sensor (TPS) is a sensor used to monitor the position

of the throttle in an internal combustion engine. The sensor signal is used by the engine control unit (ECU) as an input to its

control system. The ignition timing and fuel injection timing are altered

depending upon the position of the throttle, and also depending on the rate

of change of that position. Engine control units control engines by determining the amount of fuel,

ignition timing and other parameters, by monitoring an engine through sensors,

and reading values from multidimensional maps.

12. Traction motor

• Electric motor providing the primary rotation a torque of a machine, usually

for conversion into linear motion.

• DC series-wound motors, running on approximately 600 volts.

• The availability of high-powered semiconductors such as thyristors has now

made practical the use of much simpler, higher-reliability AC induction motors.

FIRING ORDER IN CYLINDER

Front End firing order

Left Bank Right Bank

Rear End

Lube Oil & Water

Pumps Governor

• 9

• 10

• 11

• 12

• 13

• 14

• 15

• 16

• 1

• 2

• 3

• 4

• 5

• 6

• 7

• 8

Engine Air Inlet &

Flywheel

1

9

3

11

4

12

2

10

8

16

6

14

5

13

7

15

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� Truck Machine Shop (TMS) In this shop they make wheel, axle. After making axle and wheel they assemble the axle and

wheel. In TMS the assembled wheel, axle, bull gear, bearing cap of axle etc.

Bogie:

There are two types of bogie

•Co-Co bogie

•Bo-Bo bogie

1. Co-Co bogie:

Co-Co bogie has three axles and six wheels.

2. Bo-Bo bogie:

Bo-Bo bogie has two axles and four wheels.

Manufacturing of bogie:

There are two of manufactured bogies

1. Fabricated bogie:

In fabricated bogie, bogie made by the cutting and welding. In DLW fabricated bogie uses

mostly.

2. Casting bogie:

In the casting bogie, bogie is manufactured by casting

Important parts of bogie:

1. Bogie frame:

A bogie is a wheeled wagon or trolley. In mechanics terms, a bogie is a chassis or

framework carrying wheels, attached to a vehicle. Bogie on which super structure

and under frame is mounted. It is two type Co-Co and Bo-Bo bogie. Co-Co has three axles

and six wheel and Bo-Bo has two axles and four wheel.

2. Axle:

EMD engine axle has three holes but in ALCO engine axle has eight

Holes.

3. Wheel

4. Bull gear

5. Suspension tube

6. Axle boxes

7. Traction motor: Electric motor providing the primary rotational torque of a machine,

usually for conversion into linear motion. DC series- wound motors, running on

approximately 600 volts.

8. Brake riggings items

9. Air pipe

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Organizational Strength

�A flagship production unit of Indian Railways offering complete range of

products in its area of operation with annual turnover of over 2124 Crore.

�State of the art Design and Manufacturing facility to manufacture200

locomotives per annum with wide range of related productsviz. DG Sets, Loco

components and sub-assemblies.

� Supply of spares required to maintain Diesel Locomotives and DG sets.

�nbeatable trail-blazing track record in providing cost-effective, eco-friendly

and reliable solutions to ever increasing transportation needs for over four

decades.

�Fully geared to meet specific transportation needs by putting rice- Value -

Technology equation perfectly right.

�A large base of delighted customers among many countries viz. Myanmar, Sri

Lanka, Malaysia, Vietnam, Bangladesh, Tanzania, Angola, to name a few,

bearing testimony to product leadership in its category.

Our Quality Policy

�Quality, Environment, Health & Safety olicy

Diesel Locomotive Works is a roduction nit of Indian Railways,

manufacturing Diesel-electric Locomotives, Diesel Generating sets and their

spares for Indian Railways, Non-Railway Customers and exports.

We are committed to achieve excellence by:

� Continual improvement of the Quality, Environmental and Health &

Safety - at- work -place performance.

� reventing pollution by all means including minimizing resource

consumption and waste generation using cleaner technologies, material

substitution and process changes.

� reventing all injuries and loss of property including environmental

performance through continuous safety inspections.

� Striving for compliance with all applicable Environmental and Health &

Safety legislations.

� Striving for "Right first time" and safe working practice through system

improvement and training.

� Enhancing Customer Satisfaction through improvement in reliability and

performance of products.

� reventing all employees from occupational diseases and health

hazards.

We shall:

� Set objectives & targets and periodically monitor their progress through

internal audit and management review.

� Communicate Quality, Environment and Health &Safety policy to the

employees and to make it available to the public on demand.

Environmental/Societal Orientation

� Environmental Management

A healthy and congenial environment alone can produce and promote healthy

citizens we firmly believe. In order to have a clean and green DLW, we have a

well defined integrated environmental policy. This promotes an ever motivated

work-force, giving rise to products of International standard.

� Environmental Objectives:

• Reduction in Resource consumption

• Reduction in Fire Emergencies -10% every year

• Improvement in Emergency preparedness

• Monitoring of water & ambient air periodically

� Sewage Treatment Plant:

ST is mainly concerned with the treatment of domestic and industrial

sewage. The treated water is used for irrigation purpose up to nearby Lohta

farm and kitchen gardening at DLW premises. The digested sludge is sent to

sludge drying beds, later to be used as manure. Methane gas mainly produced

from the digester is collected in the gas holder and supplied to the canteen.

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� Industrial Effluent Treatment Plant:

IET does the job of treatment of industrial effluent which mainly contains oil

and grease. The treated water is sent to nearby villages for farming and kitchen

gardening at DLW.

� Chromium Treatment Plant:

CT deals with the treatment of effluents from CR shop (Chrome lating

Shop). This has varying concentration of hexavalent chromium. This hexavalent

chromium is converted into trivalent chromium in acidic condition and is

precipitated. This sludge, after drying in the form of cakes, is stored in a

covered tank made of concrete. Water after treatment is used for irrigation in

nearby villages.

� Occupational Health & Safety Management:

DLW is OHSAS-18001 certified since September; 2005.OHSAS formulates the

work-procedures, defines hazards, assesses the risks involved therein and

generates awareness regarding use of personal protective equipments at

workplace. This enhances safety at work-place, reduces chances of accidents

and makes workers more confident leading to increase in productivity.

OHS Objectives:

• Reduction in HOD cases -10% every year

• Improvement in use of PPEs (100%)

• Recharging of Ground water

INNOVATIONS IN GLOBAL LOCOMOTIVES Why diesel-electric locos? Diesel is a non renewable source of energy and can’t be replenished once finished. So why not go for electric locomotives, which pick up electrical power from an overhead wire or a third rail laid beside the track? When I asked this question from my project guide, he simply answered that the cost of electric transmission lines is huge and also The first cost of an electric locomotive is far greater than a diesel locomotive. Hence even at those places where transmission lines have been laid, diesel-electric locos are still used! Recent trends Recent innovations in technology have been driven by a desire to find safer, faster, and more reliable means of getting from place to place. For passenger transportation, speed and convenience are primary goals. For freight transportation, speed, reliability, and efficiency, or carrying more cargo for less money and arriving on time, have been the motivating factors. The diesel-electric locomotives cannot go on indefinitely and there is need to look for smarter methods in locomotive transport sector. Most modern transportation systems rely on petroleum for energy, but this source of energy is finite and creates serious environmental effects when used in the internal-combustion engine. Research into alternative fuel sources, such as electrical storage, natural gas, methanol, ethanol, fuel cells, and solar energy, will continue in order to ensure a reliable supply of energy for the transportation systems of the world. Several new forms of propulsion are also being investigated. Several technologies that are shaping society in a variety of ways will likely characterize the future of locomotive transportation. Intelligent transportation systems apply the latest advances in computers and electronics to better control vehicle operations. Computerized road maps used with the Global Positioning System (GPS) help drivers to navigate. Research is also being conducted into improving the materials used for constructing the locomotives. Composite material, which is a hybrid consisting of many different component materials, can provide lightweight, extremely strong, and highly durable material for loco construction. With the lighter weight, locos can become more fuel efficient. Explained on the following page is the working of a magnetically levitated locomotive that very surely is the technology of the future!

VALUE ADDITION � After completing this project, I can now feel that I have learnt a great deal and

also had this excellent opportunity to get some useful exposure of industry. � I have had a closer look on the various machining operations in my shop. � I had a chance to visit different shops and learnt about their working and

had a good idea about an EMD- LOCOMOTIVE.

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Documents

dlw training report, varanasi