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The globe is shrinking. The world is taken over by the technicians. A day after daya new technology arises. A technician without practical knowledge is zero, don’t matter how many books you have studied. Practical know how is must to be successful. Industrial training is the bridge for a student that takes him from the world of theoretical knowledge to that of practical one. # Training in a good industry is highly conducive for: 1.Development of solid foundation of knowledge and personality. 2.Confidence building. 3.Pursuit of excellence and discipline. 4.Enhancement of creativity through motivation and drive which helps to produce professional and well trained for the rigorous of the job/society. The present report has been done as an industrial training of four weeks for the completion of 4th semester of Production & Industrial Engg. Diploma. During the training I got the exposure to various equipment and machines their maintenance and technology concerning the repairing the Diesel Locomotive and hencewas assisted in developing selfconfidence. The training helped me in implementing mytheoretical knowledge to the actual industrial environment.This training at the “NORTHERN RAILWAY DIESEL SHED LUDHIANA” is definitely going to play an important role in developing an aptitude for acquiringknowledge hard work and self confidence necessary for successful future.
Few tasks are more enjoyable and fulfilling than acknowledging my gratitude toall those. I am overwhelmed. I take this opportunity toexpress my sincere thanks to the management of “NORTHERN RAILWAY DIESELSHED LUDHIANA” of permitting me to observe and study the whole setup of factory. Tiwari. I owe more than a debt of gratitude to Mr.Senior Chief Instructor Mr.K. . P. in every game of life these are multitude of players whose are the realheroes and this experience there are many loyal and phenomenally selfless friends. who have helped in this effort in so many ways. and specially Thanks to Mr. Kuldeep Rai (Principal). I am equally thankful to my faculty teacher for providing me this opportunity to work with such a big company.ACKNOLEDGEMENT In these four weeks of industrial training. Sarbjeet Singh (Mechanic) & all the staff for their corporation & guidance made it possible to complete the work. I wish to my attribute my profoundsense of gratitude without whose generous co-operation and co-ordination it would have been highly difficult for me to have such a successful training experience in theorganization. co-workers and my bosses in industry.
The staying capacity in thehostel is 72 and is having 38 double-bedded rooms. under whom the officers DME-I. The Training School consists of 5 classrooms and various working models of mechanical and electrical sub assemblies of WDM2 locos. ACMT & SMM/Storesare working.NORTHERN RAILWAY. The total kilometers earning is approximately 22 lakh kilometers per month and the shed is running a mail link of 96 locos consisting of various prestigious Mail/Express trains. In addition to this. indoor games etc. Further the total holding of shed was increased to 150 locos in the year 1993-94. . DME-II. This training School is being mainlyutilized for training of running staff for Diesel conversion and refresher courses of FZR & UMB division. ADME/R/Elect. WDM2. Mech. Diesel Shed. which is headed byunder the dynamic control of Sr. It is also equipped with the recreation facilities &gymnasium with high-tech exercise machines.1977. WDM3A & WDG3A. Present loco holding of Diesel Shed. Ludhiana is 170 having different types of locos i. Diesel Shed.09. DIESEL SHED. Later. Ludhiana is presently the biggest shed on the Northern Railway and the 3rd largest on Indian Railways. Initially. the shed wasdesigned to home 60 WDM2 locos. Ludhiana is also having a Diesel Training School and Hostel attached to it.e. LDH is ISO0-14001 Certified Shed.Divl.Engineer (Diesel). ADME/H. LUDHIANA Chapter-1 INTRODUCTION _____________________________________________________________ Diesel Shed Ludhiana came into existence on 29. this is also being utilized for imparting training tothe maintenance staff of the shed. ADME/R/Mech. it was expanded to home 100 WDM2 locos inthe year 1987-88. Diesel Shed.. Presently.
however.its application for railway propulsion was considered. as well as the difficulty inherent inmechanically applying power to multiple driving wheels on swivelling trucks (bogies). Steady improvements in the Diesel engine's design (many developed by Sulzer Ltd.Rudolf Diesel patented his firstcompression ignition enginein 1892. Currently. offering greater flexibility and performance than thesteam locomotive.OVERVIEW Earlyinternal combustion engine-powered locomotives used gasolineas their fuel. Soon after Dr.of Switzerland. with whom Dr. as well as substantially lower operating and maintenance costs. Diesel was associated for a time) gradually reducedits physical size and improved its power-to-weight ratio to a point where one could bemounted in a locomotive. almost all Diesel locomotives are Diesel-electric. Once the concept of Diesel-electricdrive was accepted the pace of development quickened. due to the poor power-to-weight ratio of the early engines. . By the mid 20th century the Diesel locomotive had become the dominant type of locomotive in much of the world. Progress was slow.
1.1 Various Sections In Diesel Shed:# Turbo Section # Expressor Section # Compressor Section # Power Assembly Section # Cylinder Head Section # Machine Shop # Cross Head Section # Water Pump & Lube Oil Section # Radiator Section # Traction M/C # Governor Section # Gauge & Valve Section # Air Brake Section # Electrical Complaint Room # Auxillary M/C Section # Electrical Test Room # Magnaflux Section # Bogie Section # Valve Grinding Section # Contactor & Relay Room # Zyglo Testing Room # Fip Section # Tsc Balancing Section # Draftsman Room # Battery Section # Metallurgical Lab # Spectro Section # Scrap Yard .
At present. Diesel Shed.1 Turbo Supercharger Section Turbo Supercharge is a machine.2 Fip & Injector Section This section is responsible for maintaining the fuel injection pump and the injector of diesel locomotives. The fuel injection pump is responsible for maintaining desired pressure to inject the fuel. Ludhiana has different sections for electrical and mechanical repairs & maintenance. Brief details are as under:1. 1. which uses exhaust of the diesel engine tocompress the intake air to improve the engine efficiency to about 1.Various Sections In Diesel Shed To maintain various parts of locomotives. The strengthof staff of this section is 7. 1. . overhauled and tested in this section. (i)15mm FIP (ii)17mm FIP All these subassemblies are being dismantled. Two types of FIPs are being used at present. 4types of TSCs are being overhauled in this section. 1. whereas the injector has the duty to spray the fuel inthe cylinder after atomization.5 times. (i)ALCO Turbo Supercharger (ii)ABB Turbo Supercharger (iii)Napier Turbo Supercharger (iv)Hispano Suiza Turbo Supercharger All these TSCs are fully dismantled and overhauled in this section.
5.1. Steel cap pistons are being used in fuel efficient locomotives. two exhaust and two inlet valves. 16 Nos. the valve angle is 30 Degree. In fuel-efficient locomotives.1. 1. This section is responsible for maintaining this subassembly. The head is completelydismantled and after cleaning and mating the valve & valve seat and overhauling thecomplete components. Cross Head Section Crosshead is a subassembly.Complete expressor or compressor is dismantled and overhauled in this section as per Work Instructions issued to the section. whereas in conventional locomotives it is 45 Degree. 16 power assemblies are being used in one locomotive. cylinder heads are there in one locomotive. The pistons and connecting rods are dismantled. The staff strength of the section is about 25. whereas aluminium pistons are being used in conventional locomotives. Two types of pistons are being used in thelocomotive.6. Cylinder Head Section This section is responsible for maintenance and overhauling of cylinder headsof diesel locomotives.1. The shed has switchedover to barrel shape piston rings to provide better fuel efficiency. Each cylinder head has four valves.1.4 Power Assembly Section The piston and connecting rod assembly is called as power assembly. the head is made ready for service in this section after varioustests. The staff strength of section is about 10. 1. which is operated by camshaft to . zyglo tested and again are made ready for service in this section. cleaned.1. The staff strength of this section is about 7. 1.3 Expresser & Compressor Section The expresser is used to maintain air pressure and vacuum pressure for breaking system in the locomotive.
1. traction motors. Both the pumps are gear driven through crankshaft split gear train.1. universalshaft. one for exhaust and other for air inlet Cross heads are completely dismantled and overhauled and also the valve lever mechanism is completely dismantled and overhauled in this section. Pump Section The pump section is responsible for overhauling water pump and lube oil pumpof the locomotive.whereas these are roller bearings in about 50% of . over speed trip assembly is responsible for preventing the enginefrom over-speeding. Miscelleneous Sub-assembly & Heat Exchanger Section This section is responsible for maintaining rear truck traction motor blower which is belt driven. The staff strength of this section is 4. which aresupplied from a generator driven by the diesel engine.7.8. The cross heads operate the valve levers through two bush rods. The motors aresuspended through suspension bearing which is plain bearing in some locomotives. overhauled and made ready for service in this section.1.9. The selfcentrifuging unit of locomotive is also overhauled inthis section.Every loco is having one water pump and one no. A locomotive is driven on line through 06 No.operate the valvelever mechanism of the cylinder heads. The staff strength of this section is about 4. front truck traction motor blower which is gear driven. such as radiator. Both the pumpsare cleaned. eddy current clutch gear box used to providedrive to radiator fan. tested &overhauled in this section. which is used to drive radiator fan. In addition to above. 1. lubricating oil pump. various heat exchangers. These motors are fitted on 6 Nos.1.axles and connected to axles through a bull gear pinion arrangement. compressor after cooler and engine lube oil cooler are cleaned. 1. There are 16 cross heads in one locomotive.Bogie Section This section is responsible for complete overhauling of undergear of thelocomotive. turboaftercooler.
1. Yearly Section Yearly section is used for complete overhauling of locomotive. 1. Staff strength of this section is about 90. lube oil bypass valve of the locomotive. engine block and removal of various mechanical subassemblies.10. central buffer couplers on each side for connection tothe train.11. horns etc. Staff strength of this section is 2. The yearly section carries out 24monthly and 48 monthly schedules of the locomotives in which engine and varioussubassemblies are overhauled completely. 1. side bearers and one no. 2 on each side to bear various pumps during operation. Each bogie has two nos. which are responsible for recording . fuel relief valve. Staff strength in this section is about 70. Valve Section This section is responsible for maintaining fuel regulating valve. The chassis is also having mounted 4 Nos. The loadsharing between the central pivot and the side bearer is in the ratio of 60:40.1.1. lube oil relief valve. sanders. Two bogie frames areused to house six axles and wheels and called as front bogie and rear bogie. Staff strength of this section is about 50. Air Brake Section Air brake section is responsible for overhauling of brake valves of air brakesystem and other safety items such as wipers. The load of locomotive is shared by each bogie.The valves are overhauled and are set at a required pressure as per MaintenanceInstructions. In addition to it.1.13. variousgauges are also being maintained by this section.lube oil regulating valve. central pivot. The brakingarrangement for the locomotives is given through 8 brake cylinders. 1. The chassisof the locomotive is having 2 Nos.locomotives.1. 4 on each bogie and various brake riggings. buffers.12. brake shoes and brake blocks. Speedometer Section The speedometer section is responsible for maintaining speedometers of thelocomotive.
2. 12 monthly and 16monthly schedules of diesel locomotives. (i)Woodward governor (ii)GE or electro hydraulic governor (iii)Microprocessor based governor. Mailsection is responsible for maintenance of diesel engine.2 Goods Section Goods section is also having goods mech. Staff strength of this section is about 16.undergears etc. various mechanicalsubassemblies.and indicating the speed of thelocomotive. for trip schedule. 1. monthly schedule and quarterly schedulefor mail and passenger locomotives. monthly schedule and quarterly schedule for goodslocomotives.The governor of the locomotive is responsible for maintaining constant speed of theengine as per requirement at every notch. for trip schedule. the shed has 3 types of governors.14. Governor Section Governor section is responsible for maintenance of governor of the locomotive.2 Minor Repairs Sections 1. Goods section isresponsible for maintenance of diesel engine.1 Mail Section Mail Section is having 2 sections i.2. 1. and Mail Elect. section. undergears etc.2. and goods electrical. various mechanical subassemblies. 1. At present.e.3 Quarterly & Half Yearly Section Quarterly and half yearly section is responsible for 8 monthly.1. . Mail/Mech. 1.
7 BLOCK DIAGRAM OF DIESEL LOCOMOTIVE SHED .1. engine blocks and various major subassemblies.5 M & P Of The Shed lift bogies. The shed is also having 3 Nos. Every minor repair bay i.2. mail. 1. fork lifters for material handling. These are used for handling varioussubassemblies. quarterly half yearly sections arealso having 3 tonne self operated cranes which are used to lift various subassemblies of the locomotive.2.4 Out-Of-Course Section OOC section is responsible for attending various major repairs of the locomotives.2. goods. 0ne10tonne and the other is 3tonne crane.which cannot be covered during minor schedule. 1. Heavy Repair Bay subassembly sections are having two cranes.6 SCHEMATIC DIAGRAM OF DIESEL – ELECTRIC LOCOMOTIVE img.2.e.1 1.
577 sq.8 SALIENT FEATURES # Sanctioned staff strength = 1316 # Staff on roll = 1195 # Total covered area = 12. # Average off take of diesel oil per day = 0. # Stock items in the stores depot. # Berthing capacity = 32 locos. # Lube oil storage capacity = 350 kiloliters. # Average kms earned/month = 21. # %age of staff housed = 21%.72 =2.61 lakh kilometers.30 =3. # Average off-take of lube oil per day = 2700 liters (approx).3 lakh liters (approx). meters. # Fuel storage capacity = 730 kiloliters.03 .2.A Diesel locomotive is a type of railroad locomotive in which the prime mover is a Diesel engine 1. = 1969 # Present mail link = 96 # Present loco holding = 170 (a)WDM2 = 62 (b) WDG3A = 44 (c) WDM3A = 64 Total =170 Direct maintenance staff per loco SFC Mail (Lts/1000GTKM) (2008-09) SFC Goods (Lts/1000GTKM) (2008-09) =4.
23. Displacement (FAD). of cylinder.3 m3/hr.Types Of Machinery Machinery Single Stage Air Compressors Quantity Specification 11 Horse Power (HP). Working Pressure. Tank Capacity in litres.188.8.131.52 m3/hr.160.3. No. Tank Capacity in litres. Reciprocating Air compressors- Two Stage Air Compressors 28 Horse Power (HP). .250. of cylinder. No. Displacement (FAD).7 kg/cm 98 PSI.12 kg/cm' 175 PSI.2. Working Pressure.
Grinding MachinesHand Grinders 15 Grinding/polishing Disc Dia.5 kg (approx..150X20X12.2950 RPM Wheel Size.125mm Spindle Thread.) Bench Grinders 6 No-Load Speed.250 W .11000 RPM Weight.7 mm Input Power.M14 Power Input.2.1100 W No-Load Speed.
7.3.254 mm Admit Between centre.7 KW .30-1235 RPM No.4250 mm Height of Centre.5 KW Elevating motor.8 Power required.3150 mm Spindle Speed Range.LathesHeavy Duty Geared Precision Lathes 4 Length of Bed.5 Horse Power Drilling MachnesHeavy Duty Radial Drill Machines 3 Diameter of column.2650x1400 Power supply (Main Motor).50 mm Working surface of base plate. of Spindle Speeds.
7 tons Length of Side Moving Span.10 m Length of Sliding (forward moving) Span.30 m .25 tons Length of Side Moving Span.T)2 Capacity.30 m 1 Electric Over-Head Travel Double Girder Cranes 1 Capacity.O.CranesHand Operated Travelling Cranes(H.10 m Length of Sliding (forward moving) Span.1 tons Span-10 m Multi-Span Underslung Cranes Capacity.
Companies like the Tata Totors .also many foreign companies are coming to our country and setting up plants . Diploma holders are posted atleast at supervisor for industry and hence the scope of this branch is really very good.and also the pay is very high when compared to other companies. Diploma In Company Production & Industrial Engineering is an very good branch with lots of scope in the country . HINDALCO.generally the production engineering deals with various techniques of manufacturing and tools used in the manufacturing industries .companies like Toyota. Maruti and Mahindra & Mahindra. Honda. . with the sales and demand of cars going up in our country the need of good manufacturing engineers is really increasing in our country.so that means you will be surely employed in an factory atmosphere if you take this course and hence employed by companies dealing with such operations. Mercedese.Scope Of Engg. Relience Steels are really employing many freshers . Medium & small Scale Industry also plays an mportant role in recruiting jobs as Engg.it also teaches the various drawings and also how to develop them and understand them. Tata Steel. Audi. And industries like Hero Group. Bmw are really hiring many production engineers in our country because of there plants to set up plants.
Manpower Chart Category Supervisory Artisan (Skilled) Artisan (Un-Skilled) Ministerial & Others Operating Staff Grand Total (Direct & Indirect) Sanction Actual 124 885 207 90 10 1316 99 841 164 82 9 1195 Vacancy 25 44 43 8 1 121 .
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