Industrial Training Report

Diesel Locomotive Works

Varanasi

By

Ramu Verma
(Roll No- 1673440044)

Bachelor of Technology

Mechanical Engineering Department

Rajkiya Engineering College, Banda

June-July, 2019
 ABSTRACT

Industrial Training is meant to expose the students of engineering of the actual

Industrial Processes about which they have mean studying in detail from their
semesters. They have spent the last two years in gaining theoretical knowledge of
various manufacturing and assembly processes.
The four week training has exposed us to the actual application of the various
studied. The training period has being very interesting wherein we got to know how
the final product comes to the market. Each product undergoes a number of qualities
control test to bring in uniformity and quality.
Each field requires skillfully handling and training at given at each step which
will help us in the long run.
 ACKNOWLEDGEMENT

It gives us a great sense of pleasure to present the report of Industrial Training/Internship.

The Industrial Training/internship opportunity I had with DIESEL LOCOMOTIVE
WORKS was a great chance for learning and professional development. We owe special
debt of gratitude to DIESEL LOCOMOTIVE WORKS VARANASI.

We also take the opportunity to acknowledge the contribution of Mr. Saurabh Tripathi,
Head, Department of Mechanical Engineering for his full support and assistance during
the development of the project.

Signature:

Name: Ramu Verma

Roll no: 1673440044

Date: 16/10/2019
 TABLE OF CONTENTS

1. Introduction

2. History

3. Product of DLW

4. Workshops

Heavy Welding Shop

Heavy Machine shop

Sheet Metal Shop

Truck Machine Shop

5. Conclusion

6. References
 INTRODUCTION TO TRUCK MACHINE SHOP:

The shop deals with the matching various small component such
as pinion, Axial wheel, collar, gearing, gear etc.
1. Truck frame machine section
2. Centre lathe machine section
3. U.T.L section
4. Axial wheel machine section
5. Miscellaneous machine section
6. Axial wheel and box assembly section
7. Truck frame sub assembly section
8. Truck frame fabrication section
9. Truck frame assembly section
3.WHEEL SHOP:-
In this shop, repair work of the wheel and axel is under taken. As it is known that,
the wheel wears throughout its life. When at work the profile and diameter of the
wheel constantly changes. To improve it’s working and for security reason, it is
repaired and given correct profile with proper diameter.

The diameter of new wheel is-

Type Wheel dia. Distance b/w journal Journal Axel wheel seat
center (mm) size(mm) dia. (mm)

ICF 915 2159 120*113.5 172,0.25,0.35

BMEL 915 2210.2 120*179 171,0.45,0.63

Wheel can be used certain minimum diameter after which it is discarded. The
diameter

wheel when it is condemned is

S.N TYPE OF WHEEL DIAMETER IN (MM)

1. ICF/BMEL SOLID 915-813
2. ICF TIRED 915-851
3. BMEL TIRED 915-839

FIG:(2).WHEEL
5.HEAT TREATMENT SHOP:-
Heat treatment is the process of heating and cooling of a material to change its
physical and mechanical properties without changing the original shape and size. Heat
treatment of steel is often associated with increasing its strength, but can also be used
to improve machinability, formability, restoring ductility, etc. Basic heat treatment
process for steels are described in the following subsections.

FIG:(3).HEAT TREATMENT PROCESS

8.1 DIFFERENT TYPES OF HEAT TREATMENT PROCESS

1. Hardening.
2. Tempering.
3. Austempring.
4. Martempring.
5. Annealing.
6. Stress relieving.
7. Spheroid zing.
8. Normalizing
9. Case hardening.

10. Cyaniding.
11. Flame hardening.

12. Induction hardening.

13. Nitriding.

8.2 IRON CARBON DIAGRAM

FIG:(4). IRON CARBON DIAGRAM

6.BREAKING SYSTEM:-
Working-By means of frictional force between wheel and brake pad.

Mainly two types of braking system is used-

1. Air-Braking system.
2. Vacuum-brake system

10.1 AIR BRAKING SYSTEM

This is new method of braking system, which is more efficient than the vacuum
brakes. It is used at first in Rajdhani and satabdi coaches. Progress conversion of
vacuum brakes in air-brake has being undertaken.

The main parts of air-brake system are following

1. Brake cylinder.
2. Brake pipe.
3. Feed pipe.
4. Distributer pipe.
5. Angle lock.
6. House pipe.
7. Auxiliary reservoir.
8. Guards van valve & pressure gauge.
9. Isolating cock.

FIG:(5).BREAKING SYSTEM
 BRAKE PIPE-This is charged from the locomotive at 5 kg/cm3 and causes
application and release of brakes due to change in its pressure through the

locomotive control system. The pipe linked to distributor system .

FEED PIPE- It having 6kg/cm3 pressure, and keeps the auxiliary reservoir
charge at fuel pressure even when brakes are applied. Feed pipe are also
connected to the distributor valve.

DISTRIBUTOR VALVE- It is connected to the brake pipe auxiliary

reservoir and brake cylinder. It controls the pressure in the brake cylinder. It
controls the pressure in the brake cylinder in proportion to the reduction of
pressure in brake-pipe.

ANGLE COCK-It is use for alarming purpose.

HOUSE COUPLING- Both the brake-pipe and feed pipe are fitted to the
angle cock outlet for the passage of compressed air from one coach to another

mean of braided rubber and metal coupling .

GUARD VAN VALVE & PRESSURE GAUGE - These are provided in

the guards compartments. These are provided to control the train movement.

ISOLATING COCK- Use for isolating the air from one point to the other
point.

CHOKE- It is device for restricting the flow of air from one point brakes circuit to
other point. The handle of this cock is kept parallel to the pipe to indicate that it is in
open conditions .
7.SPRING SHOP:-
In this section the helical and leaf spring are prepared. For this purpose there certain
machine for testing, grading and repairing it.

FIG:(6).SPRING

The test performed on helical spring and laminated spring are-

[1] Visual and magnetic crack detection.

[2] Spring scraping mach

[3] D’ buckling

Visual and magnetic crack detection. The visual test with the help of magnifying lens
and glass the spring the is inspected of-

Corroded--------------- Fail

Deep seam of mark -------------------- Fail

Surface crack ------------- Fail

No sound defect ------------- Fail

In the magnetic testing a mixture of kerosene oil and magnetic red ink is sprayed on the spring and
inspected for the clinging of the oil droplets. If oil clings at same place if present the presence of crack.
There are variation reasons for the failure of the helical spring such as free height load test, dent
mark, corrosion and breakage.
 CAUSE PERCENTAGE OF FAILURE
Free of height 8.93%
Load test 82.08%
Dent mark, corrosion &breakage 08.39%

After the buckling test, the spring should be put on scraping machine and the camber
should be measured. In this test, the spring should be pressed quickly and camber
should be measured 2 times. The spring should be test such as, it should not be more
than ½ of the plate. In helical spring scraping, the spring is kept on the machine and
its free height us measure. Now the spring is compressed, under certain and its
compression is noted down. The compression is matched from the table provided for
springs. If the compression matches, the spring is passed otherwise rejected

VARIOUS REASONS OF SPRING FAILURE ARE AS FOLLOW

1. Over camber of the spring.

2. Short camber of the spring.
3. Leaf broken.
4. Gap between the leaves of the spring

D’ BUCKLING
On this machine, buckling is performed on laminated spring. The leaves of the springs
are assembled and pressed. Now it is put on the buckling machine axial and
longitudinal forces are applied.
8.PAINTING SHOP:-

After the coach body is fully repaired and the flooring work completed, it should be
swept and cleaned of all dust, shavings, etc., before the coach is placed in the Paint
shop for painting and polishing.

The condition of the paint on the inside and outside surfaces should be examined to
decide whether the old paint should be removed to the bare metal. Usually, extensive
corrosion repair work necessitates removal of old paint to bare metal and complete
repainting of the coach.

TOOLS AND PLANTS FOR PAINTING:-

1. Types of brushes

i) Round brushes nos. 1/0, 2/0, 3/0 & 4/0.

ii) Flat brushes nos. 25 mm, 38 mm, 50 mm, 63 mm, 75 mm, 100 mm

iii) Lettering brushes: ß Flat brushes nos. 1 to 12 ß Round brushes nos. 1 to 12

iv) Stencil brushes v) Cleaning brushes for LP sheets with soda ash

2. Scrapers
i) Shave tukes
ii) Triangular
iii) Semi circular
iv) Diagonal

3. Safety apparel
i) Goggles

ii) Helmet

iii) Gum boots

9. METAL HANDALING SHOP:-
Material Handling is the field concerned with solving the pragmatic problems
involving the movement, storage in a manufacturing plant or warehouse, control
and protection of materials, goods and products throughout the processes of
cleaning, preparation, manufacturing, distribution, consumption and disposal of all
related materials, goods and their packaging. The focus of studies of Material
Handling course work is on the methods, mechanical equipment, systems and
related controls used to achieve these functions. The material handling industry
manufactures and distributes the equipment and services required to implement
material handling systems, from obtaining, locally processing and shipping raw
materials to utilization of industrial feedstock’s in industrial manufacturing
processes. Material handling systems range from simple pallet rack and shelving
projects, to complex conveyor belt and Automated Storage and Retrieval Systems
(AS/RS); from mining and drilling equipment to custom built barley malt drying
rooms in breweries. Material handling can also consist of sorting and picking, as
well as automatic guided vehicles.

12.1 MATERIAL HANDLING EQUIPMENT

Material-handling equipment is equipment that relate to the movement, storage,

control and protection of materials, goods and products throughout the process of
manufacturing, distribution, consumption and disposal. Material handling
equipment is the mechanical equipment involved in the complete system.Material
handling equipment is generally separated into four main categories: storage and
handling equipment, engineered systems, industrial trucks, and bulk material
handling
 10.CONCLUSIONS :-

POWER SUPPLY INSTALLATIONS

 25 kV AC, 50 Hz single phase power supply for electric traction is derived

from the grid of State Electricity Boards through traction sub-stations.
 25 kV feeders carry the power from the substations to feeding posts located
near the tracks.
 The permissible variation of the bus bar voltage on the bus bars at the grid
substations is +10% and 5%.
 Feeding Post is a supply post where the incoming 25 kV feeder lines from
substation are terminated and connected to the overhead equipment through
interrupters.
 Sectioning and Paralleling Post is the supply control post situated mid-way
between two feeding posts at the neutral section and provided with bridging
and paralleling interrupters. is the supply control post situated mid-way
between two feeding posts at the neutral section and provided with bridging
and paralleling interrupters.
 Sub-Sectioning and Paralleling Post is a supply control post where sectioning
and paralleling interrupters are provided.
 Sub-Sectioning Post is a supply control post where a sectioning interrupter is
provided.

1. PRINCIPLES FOR LAYOUT PLANS AND SECTIONING

DIAGRAMS FOR 25 KV A.C TRACTION
 These principles for preparation, checking and finalization of overhead
equipment layout plans, have been framed for standardization and
guidance of Railways / Railway Electrification Projects.
 The electrical conductors over the track together with their associated
fittings, insulators and other attachments by means of which they are
suspended and registered in position is known as Over Head Equipements.
2. PANTOGRAPH
 A collapsible device mounted on and insulated from the roof of an electric
engine or motor coach for collecting current from the overhead equipment
is known as Pantograph.
 When any part of pantograph comes in between overhead wires or vice
versa, panto entanglement takes place.
 OHE defects and Pantograph defects are few reasons of Pantograph
entanglement.

3. MODERN A.C ELECTRICAL LOCO

 India becomes 24th such nation in the world to run between Boribunder to
Kurla, the 1st electric train.
 It Works on single phase AC- 25 kV, 50 Hz, supply but TMs are three phase
Induction machines.
 Traction converter consist of three types of converters in each loco-
-Line Converter
-DC Link
-Drive Converter

4. TRACTION MOTOR
 A traction motor is an electric motor used for propulsion of a vehicle, such as
an electric locomotive or electric roadway vehicle.
 Traction motors are used in electrically powered rail vehicles such as electric
multiple units and other electric vehicles such as electric milk floats, elevators,
conveyors, and trolleybuses, as well as vehicles with electrical transmission
systems such as diesel-electric, electric hybrid vehicles and battery electric
vehicles.
5. TRACTION MOTORS as DRIVES IN LOCOMOTIVES
 Transverse drives
Longitudinal drives
 11. REFRENCE:-
[1] Kuře, G. Railway technical handbook. Axleboxes, wheelset bearings, sensors,
condition monitoring, subsystems and services. Volume 1, SKF (2011). ISBN 978-91-
978966-3-4
.
[2] Hudzikowski, J.Bearings for drive systems for railway vehicles – an outline. SKF
science report, Development Centre Steyr (2005–2006), pp. 79–84

[3] www.irieen.indianrailways.gov.in/view_section.jsp/lang=0,296,437

[4] www.irieen.indianrailways.gov.in/view_section.jsp/lang=0,296,438
[5]