Summer Training Presentation, DLW Varanasi

1. 1. Summer training report on dieSel locomotive workS varanaSi

2. 2. ATUL MAURYA TTC/DLW/16/2675 MECHANICAL ENGINEERING LOVELY
PROFESSIONAL UNIVERSITY, PHAGWARA PUNJAB (INDIA)
3. 3. introduction DLW, was founded by Late Railway Minister Mr. Lal Bahadur Shastri on 23
April 1956. It is spread in 300 acres area at Varanasi. It is a production unit owned by
Indian railways , for which it manufactures dieselelectric locomotives and its spares parts.
To meet the increased transportation needs of the Indian railways it was established in
collaboration with ALCO( American Locomotive Company), USA in 1961. DLW rolled out
its first locomotive three years later, on January 3, 1964. It manufactures locomotives.
4. 4. Got its first ISO certification in 1997 and ISO-9001 and ISO-14001 in December 2002.
With technology transfer agreement from manufacturers such as GM-EMD, DLW today
produces advance locomotives having output range from 2600 to 4000 hp. At present the
latest locomotive produced by DLW; i.e. WDG 5 has capacity upto 5000 HP & trying to make
it 5500 HP. It has supplied locomotives to other countries such as Sri Lanka, Bangladesh,
Malaysia, Tanzania and Vietnam etc. DLW is supplying locos to PSUs & Industries Like
NTPC, COAL, INDOGULF etc.
5. 5. Some factS about dieSel electric locomotive DLWs annual production - 250 Cost of
one loco - 12 to 14 crore (EMD) 8 crore (Alco) Weight of one Loco - 121 Ton Fuel
Consumption; At Full Load - 540 lt/hr. Idle Load - 40 lt/hr. Max. Speed - 160 Km/hr. Dia of
Wheel - 1092 mm Wheel to Wheel Distance - 1596.5 mm Length of Under Frame - 19962
mm
6. 6. dieSel electric locomotive In a diesel-electric locomotive, the diesel engine drives an
electrical generator or alternator whose output provides power to the traction motors. There
is no mechanical connection between the engine and the wheels.
7. 7. claSSification of locomotiveS Locos, except the older steam ones, have classification
codes that identify them. This code is of the form WDG5A [ gauge ][ power ][load ][ series ]
[ sub type ] the firSt letter (gauge) W- Indian broad gauge Y- meter gauge Z- narrow
gauge(2.5 ft) N- narrow gauge (2 ft) the Second letter (motive power) D- Diesel C- DC
electric (can run under DC traction only) A- AC electric (can run under AC traction only) CABoth DC and AC (can run under both AC and DC tractions) B- Battery electric locomotive
(rare)
8. 8. the third letter (load type) G-goods P-passenger M-mixed traffic ; both goods and
passenger S-Used for shunting U-Electric multiple units (E.M.U.) R-Railcars the fourth
letter (SerieS) The series digit identifies the horsepower range of the locomotive. Example for
the series letter 3 means that the locomotive has power over 3000 hp but less than 4000 hp.
the fifth letter (Subtype) an optional letter or number that indicates some smaller variations
in the basic model. For ex: A for 100 hp, B for 200 hp and so on..
9. 9. 1. block diviSionS 2. engine diviSionS 3. loco diviSionS production ShopS block diviSion
1. Heavy Weld Shop 2. Heavy Machine Shop

10. 10. engine diviSion 1. Engine Erection Shop 2. Engine Testing Shop 3. Light Machine Shop
4. Sub Assembly Shop 5. Rotor Shop 6. Heat Treatment Shop 7. Turbo Section
11. 11. loco diviSion 1. Loco Frame Shop 2. Pipe Shop 3. Truck Machine Shop 4. Traction
Assembly Shop 5. Sheet Metal Shop 6. Loco Assembly Shop 7. Loco Paint Shop 8. Loco
Test Shop
12. 12. welding Shop Welding is a process which produces joining of materials by heating them
to suitable temperatures with or without the application of pressure and with or without the
use of filler material. Welding is used for making permanent joints. It is used in the
manufacturing of automobile bodies, aircraft frames, railway wagons, machine frames,
structural works, tanks, furniture, boilers, general repair work and ship building.
13. 13. Shielded Metal Arc Welding [SMAW] Submerged Arc Welding [SAW] Gas Shielded
Metal Arc Welding [MIG] Flux Cored Arc Welding [FCAW] Shielded Metal Arc Welding
[SMAW] Submerged Arc Welding [SAW] Gas Shielded Metal Arc Welding [MIG] Flux
Cored Arc Welding [FCAW] typeS of welding uSed in dlwtypeS of welding uSed in dlw
14. 14. What is sMaW?What is sMaW? It is a welding process which joins metals by heating
the metals to their melting point with an electric arc set up between the end of a coated metal
electrode and the work piece. Molten metal droplets and the molten weld are shielded from
the atmosphere by the gases produced from the decomposition of the flux coating .
15. 15. Advantages of SMAWAdvantages of SMAW Equipment used is simple, inexpensive.
Electrode provides and regulates its own Flux. This process has excellent suitability for
outdoor use lower sensitivity to wind and even for use under water. All position capability
Equipment used is simple, inexpensive. Electrode provides and regulates its own Flux.
This process has excellent suitability for outdoor use lower sensitivity to wind and even for
use under water. All position capability 08/30/13 Build the nation with welding 15
16. 16. saW Process PrinciPles SAW is a welding process which joins metals by heating the
metals to their melting point with an electric arc or arcs set up between a bare metal
electrode and the job. The arc, the end of electrode and molten pool remains completely
hidden and are invisible being submerged under a blanket of granular flux. The
continuously fed bare metal electrode melts and acts as filler rod.
17. 17. SAW Features High Productivity, high amperages may be used Easy to de-slag High
Quality Deep penetration Excellent mechanical properties Environment friendly Very little
fume No radiation Easy operation High Productivity, high amperages may be used Easy
to de-slag High Quality Deep penetration Excellent mechanical properties Environment
friendly Very little fume No radiation Easy operation
18. 18. GMaW Gas Metal Arc Welding is a welding process which joins metals by heating the
metals to their melting point with an electric arc, produced between continuous consumable
electrode wire and the metal being welded. Wire is fed continuously and automatically from
a spool through the welding gun Shielding gases include inert gases such as argon and
helium for copper and aluminum welding, and active gases such as CO2 for steel welding
Bare electrode wire plus shielding gases eliminate slag on weld bead. No need for
Applications: Used for C, Si, Cu, Ni, Ti etc. For welding tool steels and dies. For the
manufacture of refrigerator parts.

19. 19. Gas Metal Arc ( MIG ) Welding Uses continuous wire 0.6 2.0 mm as electrode Gas
shielded, inert or active gas Manual, automatic or semi- automatic process High
productivity If the wire feed speed is increased more current is drawn to burn it off .
Increasing the current increases the arc energy and therefore the heat input. This in turn
increases fusion and penetration, wire deposition rate and travel speed.
20. 20. FCAW Process Features Uses tubular wire with flux inside Gas shielded (FCAW-G) or
self shielded (FCAW-S) The flux produces a protective slag and/or gas cover High
productivity process with low spatter. Smooth arc with CO2. Argon mixtures give superior
performance Problem of high fumes which need to be extracted in enclosed areas
21. 21. 22 laser cUttinG-UPto 4MM
22. 22. 23 UnDer Water PlasMa cUttinG UPto 16 MM
23. 23. boGie asseMbly shoP A bogie is a wheeled wagon or trolley. In mechanics terms, a
bogie is a chassis or framework carrying wheels, attached to a vehicle. Usually the train
floor is at a level above the bogies, but the floor of the car may be lower between bogies.
24. 24. boGie asseMbly (eMD) Wheel and Axle assembly. Brake rigging assembly.
Traction motor & gear case assembly. Bearing adopter assembly. Final assembly.
25. 25. Axle, Wheel & Axle Box AssemBly These wheels are having wear adapted profile to
RDSO drawing.
26. 26. Dead Lever Live Lever Cylinder Lever Brake Shoe Brake Head BrAke rigging
ArrAngement
27. 27. Axle, Wheel & geAr AssemBly With trAction motor
28. 28. 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. The availability of high-powered semiconductors such as thyristors has now made
practical the use of much simpler, higher- reliability AC induction motors.
29. 29. JournAl BeArings & AdAptor The bogie frame is supported on axles through soft
primary suspension consisting of twelve single helical coil springs, two springs mounted on
each bearing adapter (axle box), to provide ride quality and equalization of wheel-set loads.
Bearing adapter are fitted with tapered roller pre-lubricated, pre adjusted & sealed bearings.
Bearing adapter single helical coil springs Sealed bearings TPU shims
30. 30. AssemBly process: PRESS BULL GEAR ON AXLE. SHIFT ABOVE ASSEMBLY AT
BEARING HOUSING FITTING STAND. FIT THE BEARING HOUSING AND BOLTING .
ASSEMBLE SEAL , CAP AND TAPER ROLLER BEARING BOLTING . NOW, SHIFT
THIS ASSEMBLY ON WHEEL & AXLE PRESS MACHINE.
31. 31. BreAkdoWn mAintenAnce Break down of machine can occur due to the following two
reasons: Due to unpredictable failure of component which cannot be prevented. Due to
gradual wear and tear of the parts of the machine which can be prevented by regular
inspection known as preventive maintenance. preventive mAintenAnce Also termed as
planned maintenance or systematic maintenance . An extremely important function for
the reduction of the maintenance cost and to keep the good operational condition of
equipment. mAintAinAnce AreA

32. 32. oBJective of preventive mAintenAnce To obtain maximum availability of the plant by
avoiding break down and by reducing shut down period to a maximum. To keep the
machine in proper condition so as to maintain the quality of the product. To ensure the
safety of the workers. To keep the plant at the maximum production efficiency. To
achieve the above objectives with most economical combination.
33. 33. mAchine shop 1. Heavy Machine Shop 2. Light Machine Shop
34. 34. 1. Conventional machine 2. NC machine 3. CNC machine 1. conventionAl mAchine: It is
a simple machine which is now an old technique. 2. numericAl control mAchine: Numerical
control is defined as a system in which the actions of the machines are controlled by the
insertion of the numerical data. In other words number controls the action. types of mAchines
35. 35. clAssificAtion of numeric control 1. point to point system: This feature is only useful for
drilling and boring operations. The machine operations are possible at specified positions. 2.
strAight line system: In this system the control can command a path operation in a single axis
at a time. 3. continuous pAth system: In this system the control instructs the machine to
make movements like 2 or 3 axis at a time. The machine may be directed to make helical or
circular path.
36. 36. computerized numericAlly controlled mAchine In CNC the control system further
energized with a mini computer or a post processor. The control unit stores the
programmed information of the work piece, the travel limits, collisions zones and the
diagnostic information etc. it also gives a feedback to the operator about the current position
and distance to be travelled etc. CNC machines have the ability to edit or alter the existing
program in no time.
37. 37. mAchines in AreA B flAme cutting cnc lAser cutting Steel plates are ultrasonically tested
before being precision cut by numerically controlled flame cutting machines or by CNC
LASER machine. The laser beam is typically 0.2 mm (0.008 in) diameter at the cutting
surface with a power of 1000 to 2000 watts. Lasers work best on materials such as carbon
steel or stainless steels because these are difficult to cut due to their ability to reflect the light
as well as absorb and conduct heat. This requires lasers that are more powerful.
38. 38. AngulAr Boring MAchine FABricAtion oF engine Block This special purpose machine
has two high precision angular boring bars. Boring bars are mounted on high precision
bearings which provide control on size during angular boring. 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
39. 39. cnc Milling MAchines CNC mills can perform the functions of drilling and often turning.
CNC Mills are classified according to the number of axes that they possess. A standard
manual light-duty mill is typically assumed to have four axes: Table x. Table y. Table z. Milling
Head z.
40. 40. 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. types oF testing

41. 41. 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.
42. 42. engine test operAtion sequence Base inspection under screen and fitting over screen.
Water circulation. Lube oil filling and check deflection crank shaft. Lube oil circulation.
Pre run on no load 3 to 5 times of duration 10 to 30 min each 400 rpm. Intermediate
runs 12 runs of 30 min duration each from 400 to 1000 rpm.
43. 43. Check over speed trip of recheck 3 times. Check bake in nozzles and set tapped
clearance. Inspection before fist hour performance. First hour performance on full load.
Base inspection. Second hour performance on full load. Attend defects of first hour
performance. Final base inspection. Check engine deficiencies. Engine clearance.
44. 44. trAnsport section In transport section there are basically two types of machine are
used for transportation purpose of the different jobs from one shop to other. Different
machines used are 1. fork lift truck 2. cranes
45. 45. Fork liFt truck Forklift is a powered industrial truck used to lift and transport materials.
46. 46. counterBAlAnced ForkliFt coMponents Truck Frame - is the base of the machine to
which the mast, axles, wheels, counterweight, overhead guard and power source are
attached. Cab - is the area that contains a seat for the operator along with the control
pedals, steering wheel, levers, switches and a dashboard containing operator readouts.
Overhead Guard - is a metal roof supported by posts at each corner of the cab that helps
protect the operator from any falling objects. Power Source - may consist of an internal
combustion engine or battery.
47. 47. crAnes A crane is a lifting machine, generally equipped with a winder, wire ropes or
chains and sheaves , that can be used both to lift and lower materials and to move them
horizontally.
48. 48. THANKS