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Dmw Patiala

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DIESEL LOCOMOTIVE WORKS PATIALA
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Introduction to DMW • DMW was setup in 1981 with the assistance of World bank. • Components manufacturing started in 1986. • Production started for first time in carbon brush shop in January1986 • It has two phases : Phase 1: It has production shops Phase 2: It has rebuilding shops
Transcript
Page 1: Dmw Patiala

Introduction to DMW

• DMW was setup in 1981 with the assistance of World bank.

• Components manufacturing started in 1986.

• Production started for first time in carbon brush shop in January1986

• It has two phases : Phase 1: It has production shops Phase 2: It has rebuilding shops

Page 2: Dmw Patiala

Objective of DMW

• Manufacturing and supply of high quality components and spares.

• Remanufacture of critical assemblies.

• Rebuilding locomotives and Power Pack.

• Incorporating latest technological up gradations.

• To enhance the performance of diesel locomotive.

Page 3: Dmw Patiala

ASSET LIFE IN YEARS

PERFORMANCE AND RELIABILITY

6 12 18 24 30

PERIODIC OVERHAULS

LOCOMOTIVE REBUILDING

Page 4: Dmw Patiala

Flow chart of Diesel Loco RebuildingLoco

Stripping

Power pack

Traction Generator

Traction motors

Engine Block

Magnet frame reclamation

Rewinding of TG

Rewinding of TMs

Engine block re-building

BogiesFrame repairs and furnishing

Bogie assy and testing

Component reclamation and Engine Assy

Power pack assy and testing

Under frame cleaning and repairs

Re-cabling, re-piping, brakes and loco assy

Loco Testing

Page 5: Dmw Patiala
Page 6: Dmw Patiala

Light Machine Shop

• It has more than 70 CNC machines.

• It produces more than 250 components.

• It has the following main sections:i. Gear section.

ii. Cam shaft section.

iii.Connecting rod section.

iv.CNC turning section.

Page 7: Dmw Patiala

Heavy Machine Shop

• Complete re-treatment of engine blocks.

• Re-treatment of magnet frames of traction motors.

• Conversion of magnet frames of 2600 HP loco to suit 3100/3300 HP locos.

Page 8: Dmw Patiala

Cylinder Liner Shop

Various important processes at CLS are:

• Cast iron honing

• Vapour cleaning

• Grit blasting

• Chrome plating

• Diamond honing

Page 9: Dmw Patiala

Power Pack Shop

• Dismantling, reconditioning and assembly of power pack.

• Load testing, specific fuel consumption testing and other type of testing

• It has following main sections:Striping sectionReconditioning section Turbo supercharger sectionGovernor room Test bed

Page 10: Dmw Patiala

Bogie Shop

• Bogie is a main assembly of a diesel engine carrying its frame, wheel and axle assembly, various springs; traction motor etc.

Page 11: Dmw Patiala

Loco Rebuilding Shop

• Water test of air dust cleaner

• Renewal of air filter housing and oil bath filter

• Replacement of radiator and radiator fan bearing

• Replacement of all gauges

• Renewal of water strips & rubber hoses

Page 12: Dmw Patiala

Designation of Diesel Locomotives• This code is of the form(WDM3A) [gauge][power]

[load][series][subtype]

W = Broad Gauge Y = Meter Gauge Z = Narrow Gauge (2' 6") N = Narrow Gauge (2')

D = DieselC = DC tractionA = AC tractionCA = Dual-power AC/DC tractionB = Battery electric (rare)

M = Mixed Traffic P = Passenger G = Goods S = Shunting L = Light Duty (Light Passenger?) (no longer in use) U = Multiple Unit (EMU / DEMU). R = Railcar (see below)

The series digit identifies the horsepower range of the loco The subtype character further refines the horse power increment

Page 13: Dmw Patiala

Project Work

• To study all the components mounted on Power Pack of diesel loco and explain complete mounting and testing procedure of power pack assembly.

• To note down all the rework done in power pack shop and quality improvement steps taken.

Page 14: Dmw Patiala

Power Pack of Diesel Loco

• It is the power generating component .

• It has an engine block of 16 cylinders v shaped inline.

• The firing order of the cylinders is 1R-1L-4R-4L-7R-7L-6R-6L-8R-8L-5R-5L-2R-2L-3R-3L

• Fuel injection takes place before 25 degrees before TDC.

Page 15: Dmw Patiala

Main components mounted on power pack of diesel loco.

• There are approximately 500 components mounted on power pack.

• A few of important are as under:

•Connecting rod •Crank shaft•Cam shaft•Cylinder liner•Engine block•Piston with rings•Gudgeon pin

•After cooler• Lube oil filter• Fuel filter• Traction alternator •Governor•Crank case exhauster motor•Over speed trip

Page 16: Dmw Patiala

Engine block

• It is received from HMS after complete retreatment.

Page 17: Dmw Patiala

Piston, cylinder liner, connecting rod

• Piston is made by Federal Mogul Goetze limited Bangalore.

• Cylinder liner is made of cast iron alloy with chrome plating on inside.

• Connecting rod is made of alloy steel.

Page 18: Dmw Patiala

Crank Shaft and Cam Shaft

• Crank shaft is imported from China and USA

• Modified cam shafts are used these days.

Page 19: Dmw Patiala

Oil Catcher and Oil Damper

• A cast aluminum oil catcher is mounted on the cylinder block and base and surrounds the periphery of the cranks shaft flange oil slinger at the power take-off end of the engine.

• Oil damper absorbs the vibrations of crank shaft.

Page 20: Dmw Patiala

Other main components

• Cylinder head• FIP : Fuel Injection Pump• Turbo Super Charger • After Cooler• OST : Over Speed Trip• Water and Lube oil pump • Traction Alternator• Governor

Page 21: Dmw Patiala

Cooling process of components

• Cylinder liner are cooled by circulating water around their periphery.

• Cooling of piston crown is done by lubricating oil.Lube oil from main bearing goes to crank pin>big

end>connecting rod>small end>gudgeon pin>piston crown.

• Cylinder heads has cooling water jacket in which water is circulated.

Page 22: Dmw Patiala

Testing of various components in PPS

• Hydraulic Testing of Engine block.

• Hydraulic Testing of Gudgeon pin.

• Hydraulic Testing of Cylinder head.

• Crack detection in connecting rod on Magna flux machine.

• Backlash testing of Water and Lube oil Pump.

• Testing of power pack

Page 23: Dmw Patiala

Testing of Power Pack

• Check all the connection of water pipes, lube oil, fuel oil etc.

• Water and fuel oil are circulated and checked for leakages (if any)

• Pre lubrication must be done.• Run the engine for five minutes.• Check the engine base screen for any foreign

material.• Load the engine gradually.

Page 24: Dmw Patiala

System wise failure percentage of 2008-09

Page 25: Dmw Patiala

Major up-gradations• Fuel efficient kit

– Savings 6-7% - Rs. 600-800 thousand per annum

• Power enhancement from 2600 HP to 3300 HP– Benefits derived:

• 3 extra coaches – earns Rs. 12 million per annum

• Better acceleration- Punctuality improves

• More AC coaches with high revenue can be attached

• Recorded increase of 8.9% in revenue during 01-02

Page 26: Dmw Patiala

Major up-gradations-contd.• Retro up-gradation of Engine Block

Retro up-gradation of blocks for higher horse power ratings by providing extra stiffeners.

• Stiffer Unit cam shaftPower up-gradation and reduced maintenance time DCW

the only unit manufacturing unit cam shafts

• 251+ cylinder heads Improved water jacket design for better cooling

• Super bowl pistons with 11.75:1 CR Lower peak firing pressures- more life

Page 27: Dmw Patiala

Major up-gradations-contd.• Conversion from DC-DC to AC-DC

transmission and roller bearing suspension– Lesser maintenance and higher reliability

• Micro-processor based governor– Maintenance free and higher fuel efficiency

• Maintenance schedulesTrip schedule: 7days to 30 days– Savings- 40 trips/320 hrs/Rs. 300 thousand/annum

First major schedule: 12 months to 24 months– Savings- 1/168 hrs/Rs. 150 thousand/annum

Page 28: Dmw Patiala

Further Up-gradations

• Power enhancement to 3600 HP Prototype engine success fully tested Adaptation of electrics under process

• Micro-processor based propulsion control systemGE designed system for self diagnostics and in-built safety

systemsPrototype locos under trial

• Variable fuel injection timing Prototype engine success fully tested

Page 29: Dmw Patiala

Rework done in PPS

Lube oil strainer was not set because it was not aligned in vertical direction so gasket like material was fitted along the periphery of strainer and bracket

• Rework was done on turbocharger support by enlarging and tapping due to its holes was out.

• Ovality (0.003”) of 6th cylinder on right side crossed so cylinder was taken out from the block

• Rework was done on L.O.P. by enlarging all holes of location plate and L.O.P

Page 30: Dmw Patiala

Quality improvement steps taken in PPS

• Modification in push rod assembly with pressed ends

• Use of 18mm FIP to provide more fuel.

• Improved FIP tube with auto FrettageIncreases fatigue strengthCan bear high pulsating pressure

Page 31: Dmw Patiala

Thanks


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