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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
TECHNICAL INFORMATION
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
Overall Length 17620 mm
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Wheel Diameter 921 mm
Gear Ratio 18 : 93
Maximum Speed 100Kmph
Diesel Engine Type: ALCO 251-B 12Cyl. V- Engine
HP 2300
Transmission Electrical AC/DC
Brake IRAB-1
Loco Air, Dynamic, parking
Train Air
Fuel Tank Capacity 3000Litres
� 2300 HP METER GAUGE LOCOMOTIVE
TECHNICAL INFORMATION
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.
Wheel Arrangement Co-Co
Track Gauge 1000 mm Meter Gauge
Weight 102 t
Overall Length 17620 mm
Wheel Diameter 921 mm
Gear Ratio 18 : 93
Maximum Speed 100Kmph
Diesel Engine Type: ALCO 251-B 12Cyl. V- Engine
HP 2300
Transmission Electrical AC/DC
Brake IRAB-1
Loco Air, Dynamic, parking
Train Air
Fuel Tank Capacity 3000Litres
� 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
Wheel Arrangement Co-Co
Track Gauge 1067 mm Cape Gauge
Weight 114 t
Overall Length 18632 mm
Wheel Diameter 1000 mm
Gear Ratio 19 : 92
Maximum Speed 100Kmph
Diesel Engine Type: ALCO 251-C 16Cyl. V- Engine
HP 3000
Transmission Electrical AC/DC
Brake IRAB-1
Loco Air, Dynamic
Train Air
Fuel Tank Capacity 6000Litres
� 1350 HP METER GAUGE LOCOMOTIVE YDM4
TECHNICAL INFORMATION
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
Overall Length 15600 mm
Wheel Diameter 965 mm
Gear Ratio 18: 93
Maximum Speed 96Kmph
Diesel Engine ALCO 251 D 6Cyl. In line.
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HP 1350
Transmission Electrical AC/DC
Brake IRAB � 1 system / 28LAV-1
Loco Air, dynamic, parking
Train Air / Dual (Air and Vacuum)
Fuel Tank Capacity 3000Litres
� BROAD GAUGE MAIN LINE FREIGHT LOCOMOTIVE WDG 3A
TECHNICAL INFORMATION
Diesel Electric main line, heavy duty goods service locomotive, with 16 cylinder ALCO engine and AC/DC traction with micro processor controls
Wheel Arrangement Co-Co
Track Gauge 1676 mm
Weight 123 t
Length over Buffers 19132 mm
Wheel Diameter 1092 mm
Gear Ratio 18 : 74
Min radius of Curvature 117 m
Maximum Speed 105Kmph
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
TECHNICAL INFORMATION
Diesel Electric Locomotive with micro processor control suitable for main line mixed Service train operation.
Wheel Arrangement Co-Co
Track Gauge 1676 mm
Weight 117 t
Max. Axle Load 19.5 t
Length over Buffer 18650 mm
Wheel Diameter 1092 mm
Gear Ratio 18 : 65
Maximum Speed 120Kmph
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
Fuel Tank Capacity 5000litres
� BROAD GAUGE SHUNTING LOCOMOTIVE WDS 6AD
TECHNICAL INFORMATION
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.
Wheel Arrangement Co-Co
Track Gauge 1676 mm
Weight 113 t
Length over Buffer 17370 mm
Wheel Diameter 1092 mm
Gear Ratio 74 : 18
Maximum Speed 50Kmph
Diesel Engine Type: 251 D-6Cyl. in-line
HP 1350 / 1120 HP (std.)
Transmission Electric AC / DC
Brake IRAB-1
Loco Air
Train Air
Fuel Tank Capacity 5000litres
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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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