Summer training report

on

dieSel locomotive workS varanaSi

SHAILESH SHUKLA CT-1674/09
MECHANICAL ENGINEERING
CAET, ETAWAH
 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

diesel–electric 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.
 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 PSU’s & Industries Like NTPC, COAL,

INDOGULF etc.
 Some factS about dieSel
electric locomotive
 DLW’s 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
 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.
 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)
CA- Both DC and AC (can run under both AC and DC tractions)
B- Battery electric locomotive (rare)
 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……..
 production ShopS

1. block diviSionS
2. engine diviSionS
3. loco diviSionS

 block diviSion

1. Heavy Weld Shop

2. Heavy Machine Shop
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
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
 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.
typeS of welding uSed in dlw

 Shielded Metal Arc Welding [SMAW]

 Submerged Arc Welding [SAW]
 Gas Shielded Metal Arc Welding [MIG]
 Flux Cored Arc Welding [FCAW]
 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 .
 Advantages 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

08/30/13 Build the nation with welding 15

 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.
 SAW Features
••High
HighProductivity,
Productivity,high
high
amperages
amperages
may
maybebeused
used
••Easy
Easyto
to de-slag
de-slag
••High
HighQuality
Quality
••Deep
Deeppenetration
penetration
••Excellent
Excellentmechanical
mechanical
properties
properties
••Environment
Environmentfriendly
friendly
••Very
Verylittle
littlefume
fume
••No
Noradiation
radiation
••Easy
Easyoperation
operation
 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 Applications:
as CO2 for steel welding •Used for C, Si, Cu, Ni, Ti etc.
•For welding tool steels and dies.
•For the manufacture of refrigerator parts.
 Bare electrode wire plus shielding gases
eliminate slag on weld bead. No need for
Gas Metal Arc ( MIG )  Uses continuous wire 0.6 – 2.0
Welding 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.
 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
laser cUttinG-UPto 4MM

22
UnDer Water PlasMa cUttinG UPto 16 MM

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.
 boGie asseMbly (eMD)

 Wheel and Axle assembly.

 Brake rigging assembly.
 Traction motor & gear case assembly.
 Bearing adopter assembly.
 Final assembly.
 Axle, Wheel & Axle Box AssemBly

These wheels are having wear adapted profile to RDSO drawing.

BrAke rigging ArrAngement

Live Lever Cylinder Lever

Dead Lever

Brake Shoe

Brake Head
Axle, Wheel & geAr AssemBly With
trAction motor
 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.
 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.
Sealed bearings

TPU shims

Bearing adapter

single helical coil springs

 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.
 mAintAinAnce AreA
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.
 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.

 mAchine shop

1. Heavy Machine Shop

2. Light Machine Shop
 types of mAchines
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.
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.
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.
 mAchines in AreA B
flAme cutting cnc lAser cutting
 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
Steel plates are ultrasonically tested such as carbon steel or stainless
before being precision cut by steels because these are difficult
numerically controlled flame to cut due to their ability to
cutting machines or by CNC reflect the light as well as
LASER machine. absorb and conduct heat. This
requires lasers that are more
powerful.
AngulAr Boring MAchine FABricAtion oF engine
Block
 This special purpose machine has  Components after flame cutting
two high precision angular boring and various machining operations
bars. are fit and tack welded before
 Boring bars are mounted on high taking on rollovers. Heavy Argon-
precision bearings which provide CO2 welding is done on these
control on size during angular rollovers
boring.
 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.
 types oF testing

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.
 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.
 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.
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.
 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
 Fork liFt truck

Forklift is a powered
industrial truck used to lift
and transport materials.
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.

 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.
THANKS