Summer training report

on

dieSel locomotive workS varanaSi

trainee at dlw varanaSi

PRAVEEN TIWARI

ME-7.2ROLL NO- 1109040141IEC-CET, GREATER NOIDA

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.

introduction

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.

DLW’s annual production - 250 Loco 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

Some factS about 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.

dieSel electric locomotive

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(5.6ft) Y- meter gauge (3.4ft) 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)

claSSification of locomotiveS

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……..

1. block diviSionS2. engine diviSionS3. loco diviSionS

production ShopS

block diviSion

1. Heavy Weld Shop2. Heavy Machine Shop

engine diviSion

1. Engine Erection Shop2. Engine Testing Shop3. Light Machine Shop4. Sub Assembly Shop5. Rotor Shop6. Heat Treatment Shop7. Turbo Section

Loco Division1. Loco Frame Shop2. Pipe Shop3. Truck Machine Shop4. Traction Assembly Shop5. Sheet Metal Shop6. Loco Assembly Shop7. Loco Paint Shop8. 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.

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

18

LAsER cUTTinG-UpTo 4MM

19

UnDER WATER pLAsMA cUTTinG UpTo 16 MM

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.

Dead Lever

Live Lever Cylinder Lever

Brake Shoe

Brake Head

bRAkE RiGGinG ARRAnGEMEnT

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.

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.

Assembly Process:

        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.

breAkdown mAintenAnce

mAintAinAnce AreA

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.

objective of Preventive mAintenAnce

1. Heavy Machine Shop2. Light Machine Shop

mAchine shoP

1. Conventional machine2. NC machine3. 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

mAchines in AreA b

flAme cuttinG

Steel plates are ultrasonically tested before being precision cut by numerically controlled flame cutting machines or by CNC LASER machine.

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 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.

AnGulAr borinG mAchine

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. 

fAbricAtion of enGine block

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

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.

loco & enGine test shoP

     

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

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.

water testing

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.

engine test operation sequence

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.

  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.

counterbaLanced ForkLiFt components

HYdrauLic Ladder

cranesA 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.