Summer training Report

at

DIESEL LOCOMOTIVE WORKS

VARANASI

Sam Higginbottom university Of

Agriculture, Technology And Sciences

BACHELOR OF TECHNOLOGY
(MECHANICAL ENGINEERING)
By
Shobhit Kushwaha
14BTMECH044
7th Semester

1
 ACKNOWLEDGEMENT

I would sincerely like to thank the employee and the officers of DLW

VARANASI for their help and support during the vocational training. Despite

their busy schedule. They took time out for us and explained to us the various

aspect of working of the plant from the production shop.

I would sincerely like to thank all SSE/JE who has instrumental in arranging

the vocational training at DLW VARANASI, and without whose help and

guidance the training could not have materialize.

I express my deep sense of gratitude to Shri RAM JANAM CHAUBEY

(Principal, TTC) for giving me such a great opportunity.

2
 PREFACE

The objectives of the practical training are to learn something about

industries practically and to be familiar with the working style of a

technical person to adjust simply according to the industrial environment.

It is rightly said practical life is far away from theoretical one. We learn

in class room can give the practical exposer 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 and 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 and this report is written on the basis of

practical knowledge acquired by me during the period of practical training

taken at Diesel Locomotive Works, Varanasi.

3
 CONTENTS

 Introduction to DLW

 Truck Machine Shop

 Loco Assembly Shop

 Heavy Wield Shop

 Engine Test Shop

 Conclusion

 Bibliography

4
 INTRODUCTION TO DLW

Diesel Locomotive Works (DLW) is a production unit under the ministry of

railways. This was setup in collaboration with American Locomotive Company

(ALCO), USA in 1961 and the first locomotive was rolled out in 1964. This unit

produces diesel electronic locomotives and DG sets for Indian railways and

other customers in India and Abroad.

Subsequently a contract for transfer of technology of 4000 HP Microprocessor

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

locomotives and family of 710 engines has been signed with electro motive

division of GENERL MOTORS of USA for manufacture in DLW. The

production of these locomotives has now started and thus DLW is the only

manufacturers of Diesel Electric Locomotives with both ALCO and General

Motors technologies in the world.

5
BRIEF HISTORY-

 Setup in 1961 as a green-field project in technical collaboration with

ALCO/USA to Manufacture Diesel Electric Locomotives.

 First locomotive rolled out and dedicated to nation in January, 1964.

 Transfer-of-Technology agreement signed with General Motors/ USA in

October, 95 to manufacture state-of-the-art high traction AC-AC diesel

locomotives.

 A flagship company of Indian Railways offering complete range of

flanking products in its area of operation.

 State-of-the art Design and Manufacturing facility to manufacture more

than 150 locomotives per annum with wide range of related products viz.

components and sub-assemblies.

 Unbeatable trail-blazing track record in providing cost-effective,

ecofriendly and reliable solutions to ever-increasing transportation needs

for over three decades.

 Fully geared to meet specific transportation needs by putting Price-

ValueTechnology equation perfectly right.

 A large base of delighted customers among many countries viz. Sri

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

testimony to product leadership in its category.

6
SALIENT FEATURES-

Annual production capacity 125 Locomotives

Annual turn-over (Rs) 5000 million

Total number of staff 7223

Workshop land 89 Hectares

Township area 211 Hectares

Covered area in shops 86300 m2

Covered area of other service buildings 73700 m2

Electrical power requirement 3468 KVA

(Average maximum demand)

Electrical energy consumption (units/year) 19.8 million

Standby power generation capacity 3000 KW

7
PRODUCT OF DLW-

DLW is an integrated plant and its manufacturing facilities are flexible in

nature. These can be utilized for manufacture of different design of locomotives

of various gauges suiting customer requirements and other products. The

product range available is as under:

 WDG4 4000 HP AC/AC Freight Traffic Locomotive

 WDP4 4000 HPAC/AC Broad Gauge High Speed Locomotive

 WDG3D 3400 HP AC/AC Broad Gauge Mixed Traffic Micro-Processor

Controlled Locomotive.

 WDM3C 3300 HP AC/DC Broad Gauge Mixed Traffic Locomotive.

 WDM3A 3100 HP AC/DC Broad Gauge Mixed Traffic Locomotive.

 WDP3A 3100 HP AC/DC Broad Gauge High Passenger Locomotive.

 WDG3A 3100 HP AC/DC Broad Gauge Freight Locomotive.

 WDM2 2600 HP AC/DC Broad Gauge Mixed Traffic Locomotive.

 WDP1 2300 HP AC/DC Broad Gauge Intercity Express Locomotive.

 WDM7 2150 HP DC/DC Broad Gauge Mixed Traffic Locomotive.

 WDM6 1350 HP DC/DC Broad Gauge Mixed Traffic Locomotive.

 YDM4 1350 HP AC/DC & DC/DC Broad Gauge Mixed traffic

Locomotive.

 EXPORT LOCO 2300 HP AC/DC Meter Gauge/Cape gauge Mixed

Traffic Locomotive.

8
  Diesel Generating Sets 800 KW to 2500 KW

 Spare Parts for engines, locomotives and generating sets.

DESIGN OFFICE-

Prepare diag. of each part and sent to Material Control & inform timely in any

change in any parts to relative department.

MATERIAL CONTROL OFFICE-

Prepared material list (ml) which consists diag. & qty. of each part and sent to

store departments for purchase.

STORE DEPARTMENT- After receiving of ML, Store Departments scrutiny

the ML, take Funds & vetting from Account department & then issue tenders,

Open Tenders & Purchase Order issued. After Receiving of Material inspection

has done by Inspection Department.

INSPECTION DEPARTMENT- After Receiving of Material inspection has

done by Inspection Deptt. If material is OK then Receipt Note issued by Store

Deptt and sent to Acct. Department for payment to firm. If material is not OK

Then inform to firm to collect the rejected material.

ACCOUNT DEPARTMENT- Check all the purchase, given concurrence for

purchase, vet. the ML/Requisition & payment to firms.

9
PLANNING OFFICE- Prepare JPO, Monthly Production Program,

Scheduling, Processing, Rate Fixing, Issue Work Orders, Schedule Orders,

Issue Job card & other production Documents. Preparing DLW Budget & Sent

to Rly Board.

PROGRESS OFFICE- After opening of work orders collect the prod.

Documents from PCO and hand over to user shop draw the material from depot

& given to shop & hand over the ready material of shop to user shop/store.

After completion of work, close the work order.

PRODUCTION SHOPS-

Production shops are divided in three divisions-

1. Block Divisions

2. Engine Divisions

3. Loco Divisions

BLOCK DIVISION-

1. Heavy Weld Shop

2. Heavy Machine Shop

10
ENGINE DIVISION-

1. Engine Erection Shop

2. Engine Testing Shop

3. Light Machine Shop

4. Sub Assembly Shop

1. 5.Rotor Shop

5. Heat Treatment Shop

LOCO DIVISION-

1. Loco Frame Shop

2. Pipe Shop

3. Truck Machine Shop

4. Traction Assembly Shop

6. 5.Sheet Metal Shop

7. Loco Assembly Shop

8. Loco Paint Shop

9. Loco Test Shop

SERVICE SHOPS-

1. Maintenance Areas#1, 2, 3

2. Tool Room

3. Central Transport Shop

11
PERSONNAL DEPARTMENT- Prepare payment of Staff, Leave Record,

Personal Record of every employee, Housing allotment, welfare of staff etc.

HEALTH DEPARTMENT- Having facility of Indoor & Outdoor patients.

CIVIL DEPARTMENT- Maintenance of colony quarters, up gradation of

facilities in quarters, sanitation etc.

ELECTRICAL DEPARTMENT- Maintenance of Lighting in quarters and in

workshop, electrical works in locomotive etc.

TECHNICAL TRANING CENTER- Provide training to all employees at

time to time to refresh update their knowledge.

RECENT MILESTONES & FUTURE PLAN-

MILESTONES ACHIEVED:-Transfer of technology (TOT) -- An added

feather in the cap:-

12
  Agreement with General Motors of USA for technology transfer to

manufacture high horse-power GT46MAC 4000HP AC/AC locomotive

in India;

 Only country outside North-America to have this bleeding edge

technology Many export/repeat orders complied successfully in recent

past and many more in the pipeline; Supplied more than 400 locomotives

to various nonrailway customers; Emerging as a leading manufacturer of

ALCO/ GM locomotives for developing countries.

FUTURE PLANS-

• Assimilation of GM technology to manufacture their latest 710 series of diesel

electric locomotives;

• To emerge as a globally competitive locomotive manufacturer;

• To develop as an export hub for ALCO/ GM locos for Asian market;

• To follow an export led growth strategy through continuous improvement;

Cost effectiveness and technology/ product up-gradation as a key to retain

global competitiveness by putting price-value-technology equation right.

13
 TRUCK MACHINE SHOP

Truck Machine Shop deals with marking to truck frame. Axes boxes, spring seat

etc. & machining of as per these items, marking & machining of axel color

manufacturing of various small items read for truck assembly.

This shop is divided by 10 sections.

23/01 Marking of various – component for truck frame & truck

frame

marking and milling section.

23/02 Centre Lathe Section

23/03 Turret Lathe Section

23/04 Wheel & Axle Machine Section

23/05 Axle Box & Machining Section

23/06 Wheel & Axle assembly Section

23/07 Sub Assembly Section

23/08 Truck Assembly Section

23/09 Truck, Wheel, Axle, Traction Motor Assembly Section

23/10 Rectification of axle box and other small items section.

14
MARKING & TRUCK MILLING SECTION-

This section deals with the marking of the truck frame and milling of truck

frame, Marking of axle boxes, Equalizers, spring seat, Brake Block and various

misc., items. These items marked as per drawing after marking, items moves to

machining. Truck Frame deals in the section with Horizontal machine and

Boring machine.

CENTRE LATHE SECTION-

This section deals with various type of center lathe machine. The items are

finished in this section and sent to use in other shop is SMS, LFS etc. Such as

Fuel Bracket, Bolts, Pin etc. The operation done by this section Tapping,

Turning, Facing, Grooving, Threading & Knurling etc.

TURRET LATHE SECTION-

This section has different types of turret lathe machine according to the

specification and maintains size. In these machine some for heavy duty and

some for light duty. The items is being machined in this section as hanger pin,

coupler pin, bracket lever, bolts & nuts, shafts and studs (extension shafts,

horizontal shafts etc.)

15
WHEEL AND AXLE MACHINING CENTER-

This section deals with machining of wheel & axle. Different types of machine

deals above two items.

Wheel seat dia of axle

BG = 9.938 ± 0.01

BG = 8.188 ± 0.01

Wheel Bore Dia =

BG = 9.929 ± 000

BG = 9.180 ± 000

WHEEL & AXLE ASSEMBLY SECTION-

This section deals with wheel & Axle assembly, Lube oil, Lube Oil valve

assembly and testing.

SUB ASSEMBLY SECTION-

This section deals with grinding of envier; different type of lever oil pans, brake

equalizer guide and other various items are used in TMS. Space welding is

being also in frame in track center pivot & tow oil pans used.
16
TRUCK ASSEMBLY SECTION-

In track in BG – 8 cylinder & MS 4 cylinder is used and also BG & MG both 8

pistons is used.

TRUCK ASSEMBLY AXLE & TRACTION ASSEMBLY SECTION-

This section deals with assembly of traction motor with wheel & axle assembly

of truck frame are done.

17
 LOCO ASSEMBLY SHOP

In LAS, there are step by step process for the assembled the locomotive. There is a

sequence for assemble. In LAS Electrical control equipment is fitted and control cable

harnessing is undertaken. The complete locomotive is thus assembled before being sent

onwards for final testing and spray painting. Tested engines are received from Engine

Division. Similarly under frames are received from Loco frame shop and assembled trucks

from Truck machine shop. Super structure 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.

OPERATION IN LAS-

1. Drive cap assembly

Air compressor assembly

Control stand assembly

2. Driver cap checking

Air brake piping

3. Long hood assembly

Buffer assembly

Radiator setting

4. E n g i n e s e t t i n g

18
 Compressor setting

5. Long hood setting

Auxiliary generator assembly and setting

Alternator part packing and assembly

6. Equipment assembly

Fuel oil parking

Lube oil piping

Engine water cooling piping

7. D r i v e r s h e e t s e t t i n g

Damper assembly

Air duct setting

19
 HEAVY WELD SHOP

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

M.G) Turbo support. After cooler housing items the engine block is the

principal structural member of the diesel engine. It is composite with heavy

plates thickness varying from 16mm to75mm.

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

cylinder block is made out of the piece bitted 5’’x 7’’ thickness confirming to IS

1895. The billet foundation plate and cylinder walls are built around the steel

forging saddles to form the air chambers which ensure the maximum rigidity for

successful fabrication of cylinder block special attention is paid to the following

aspects:

1. Inspection Standard.

2. Proper Materials.

3. Proper Electrodes and Flux.

4. Proper Welding Technique.

5. Welfare of Staff.

20
SEQUENCE OF FABRICATION OF ENGINE BLOCK-

1. Setup saddles foundation plates and spine on special fixture and weld

saddle spine founded on rail.

2. Setup welding of outside cylinder wall.

3. Setup of middle dock (Tack weld) with respect to target

4. Remove can bearing shim from saddle face.

5. Intermediate machining operation remark in middle deck and chamber at

top of spine.

6. Setup of inside wall and deck welded with spine.

7. Layout of plane height.

8. Intermediate machining operation: machine height of outside wall and

side wall with respect to marking and camber.

9. Setup of top deck and lifter block for filament of eye bolt and tack weld.

10.All in side (8x2Beal Welds) welding one by sub arc method.

11.Back gauging of saddle to foundation rail joint.

12.Lay out for bearing.

13.Setup for cam bearing with respect to pay out Sino12

14.Welding of the cam bearing and saddle with foundation rail bottom side.

15.Setup of cam bearing rids and welds.

16.Say out for 8’’ machining.

17.Intermediate machining operator.

21
18.Flame out counter of foundation plate to give relief clearance to free

movement of counter with respect to crank shaft.

19.Setup of side sheet and sub arc weld of side sheet and top deck.

20.Setup of full control compartment sheet and weld.

21.Intermediate machining operation mills both and to layout for end plates

considering total length and machining allowance.

22.Hydrostatic test of water compartment.

23.Setup of top end plate and weld.

24.Setup of top deck center and weld.

25.Stress relieving element.

26.Kerosene oil test for control shaft compartment.

27.Short plats.

28.Final debarring.

22
 ENGINE TEST SHOP

Engine test operation sequence

1. Bare inspection under screen and fitting over screen.

2. Water circulation

3. Lube oil fitting and check deflection crank shaft

4. Lube oil circulation

5. Pre runs no load -3 runs 5, 10, 30 minutes (400 rpm).

6. Intermediate runs 12 runs of 30 minute duration each from 400 rpm to

1000 rpm 68 to 2330 BHP.

7. Check over speed trip of recheck 3 times.

8. Check break in nozzles and set trap clearance.

9. Inspection before 1st hour performance

10. 1st hour performance on full load.

11. Base inspection.

12. 2nd hour performance on full load.

13. Attend defects on 1st hour performance.

14. Final base inspection.

15. Check engine deficiencies.

16. Engine clearance.

23
The engine test equipment area has been divided into section as follows:

FUEL INJECTION PUMP AND NOZZLE SECTION-

This section will carry out the repairing and testing of pump and nozzles.

STARTING OF DIESEL ENGINE-

For starting the engine the main traction generator is run as a DC series motor

using power from storage batteries 60 Volts.

NOTE: The crank case inspection to be made after run test as piston and all

vital parts keep ending clean and free of all repair leaks and check all level and

hold it at full mark.

24
INTERMEDIATE TEST-

INSTRUCTION FOR DC ENGINE TESTING

RPM VOLTS AMPS BHP TIME

400 140 500 100 30 MIN

500 200 700 200 30

650 290 1044 433 30

800 408 1405 820 30

900 486 1650 11500 30

1000 590 1948 1670 30

1000 610 965 840 30

1000 650 1022 950 30

1000 680 1080 1050 30

1000 700 1200 1200 30

AFTER TEST RUN-

1. Fuel pump secure

2. Check piston and linear securing.

25
RUN DOWN TEST-

It is done to check the air of the turbo charger or to ensure that the good amount

of air being supplied to the cylinder by super charger.

PROCEDURE OF ENGINE TESTING-

The following instruction should be made before engine testing:

1. Cleaning of the test bed.

2. Lifting of engine by overhead crane, capacity 30 tons.

3. Cleaning of mounting pad lowering of engine on the test bed.

4. Diagonally tightening of mounting pad bolts.

5. Completion of all the auxiliaries connection as under:

 Water system.

 LO system

 FO system

 Air system

 Governor oil system

6. Filling of water (chromate water).

7. Connection of breaking filter and filling of LO up to full mark on deep

slick.

8. Checking of crank shaft deflection maximum allowance 0.0008”

26
 9. Connection of all thermocouples.

10. LO circulations.

11.Filling of fuel oil.

12.Application of indicator cock.

AT FINAL LOAD TEST-

1. Fuel oil piping of leak.

2. LO pump and piping for leak.

3. Exhaust manifold for leak.

4. Air manifold for leak.

27
 CONCLUSION

RECENT MILESTONES & FUTURE PLAN-

Transfer of Technology (TOT):

An added feather in the cap:-

1. Agreement with General Motors of USA for technology transfer to

manufacture high horse-power GT46MAC 4000HP AC/AC locomotive in

India;2. Only country outside North-America to have this bleeding edge

technology;

3. Many export/repeat orders complied successfully in recent past and many

more in the pipeline;

4. supplied more than 400 locomotives to various non-railway customers;

5. Emerging as a leading manufacturer of ALCO/ GM locomotives for

developing countries.

FUTURE PLANS-

1. GM technology to manufacture their latest 710 series of diesel electric

locomotives;

2. To emerge as a globally competitive locomotive manufacturer;

28
3. To develop as an export hub for ALCO/ GM locos for Asian market;

4. To follow an export led growth strategy through continuous improvement

5. Cost effectiveness and technology/ product up-gradation as a key to retain

global competitiveness by putting price-value-technology equation right.

29
 BIBLIOGRAPHY

1. www.indianrailways.gov.in

2. Cris-dlw.cirs.org.in

3. www.irfca.org

30