vocational training report on dlw varanasi

1. 
Summer training report
on
dieSel locomotive workS varanaSi

2. trainee at dlw
varanaSi

PRAVEEN TIWARI
ME-7.2
ROLL NO- 1109040141
IEC-CET, GREATER NOIDA

3. introduction
DLW, was founded by Late Railway 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.

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 PSU’s & Industries Like NTPC, COAL,
INDOGULF etc.

5. Some factS about
dieSel electric
 DLW’s annual production locomotive
- 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

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. 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(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)

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. production ShopS
1. block diviSionS
2. engine diviSionS

3. loco diviSionS
 block diviSion
1. Heavy Weld Shop
2. Heavy Machine Shop

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

13. 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

15. 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.

16. TTyyppEEss ooff WWEELLDDiinnGG UUssEEDD iinn DDLLWW
Shielded Metal Arc Welding [SMAW]
Submerged Arc Welding [SAW]
Gas Shielded Metal Arc Welding [MIG]
Flux Cored Arc Welding [FCAW]

18. 
18
LAsER cUTTinG-UpTo 4MM

19. UnDER WATER pLAsMA cUTTinG UpTo 16 MM

19

21. 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.

22. boGiE AssEMbLy (EMD)
Wheel and Axle assembly.
Brake rigging assembly.
Traction motor & gear case assembly.
Bearing adopter assembly.
Final assembly.

23. AxLE, WhEEL & AxLE box AssEMbLy
These wheels are having wear adapted profile to RDSO drawing.

24. bRAkE RiGGinG ARRAnGEMEnT
Live Lever Cylinder Lever
Dead Lever
Brake Shoe
Brake Head

25. Axle, wheel & GeAr Assembly with
trAction motor

26. 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.

27. Assembly Process:
 PRESS BULL GEAR ON AXLE.
 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.

28. 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.

29. 
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.

30. mAchine shoP

1. Heavy Machine Shop
2. Light Machine Shop

31. 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.

32. 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.

33. 
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

34. 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.

35. loco & enGine test
shoP


36. 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.

37. 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.

38. 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.

39. 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.

40. 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

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

42. 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.

43. HYdrauLic Ladder


44. cranes
A crane is a lifting
machine, generally
equipped with
a winder, wire
ropes or chains and sheav
es, that can be used both
to lift and lower materials
and to move them
horizontally.