K.N.G.D MODI ENGINEERING COLLEGE

DEPARTMENT OF MECHANICAL ENGINEERING

PRESENTATION ON : DIESEL LOCOMOTIVE WORK

SUBMITTED BYSHUBHANKAR SINGHROLL NO.- 1319540087

SUBMITTED TONUPUR MEHTAAsst. Professor

OUTLINE

Introduction of DLW Classification Production Shop Sub Assembly Shop Heat Treatment Shop Loco Assembly Shop Engine Erection Shop

Introduction of DLWo DLW, was founded by Late Railway Minister Mr. Lal Bahadur Shastri on 23 April 1956.

It is spread in 300 acres area at Varanasi.

o It is a production unit owned by Indian railways , for which it manufactures diesel–electric locomotives and its spares parts.

o To meet the increased transportation needs of the Indian railways it was established in collaboration with ALCO( American Locomotive Company), USA in 1961.

o DLW rolled out its first locomotive three years later, on January 3, 1964. It manufactures locomotives

SOME FACTS ABOUT DIESEL LOCOMOTIVE WORKS

DLW’s annual production - 250Cost of one loco - 12 to 14 crore (EMD) 8 crore (Alco)Weight of one Loco - 121 TonFuel Consumption; At Full Load - 540 lt/hr. Idle Load - 40 lt/hr.Max. Speed - 160 Km/hr.Dia of Wheel - 1092 mmWheel to Wheel Distance - 1596.5 mm Length of Under Frame - 19962 mm

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

PRODUCTION SHOPS

BLOCK DIVISION

ENGINE DIVISION

LOCO DVISION

BLOCK DIVISION

HEAVY WELD SHOP

HEAVY MACHINE

SHOP

ENGINE DIVISION

LIGHT MACHINE SHOP

SUB ASSEMBLY SHOP ROTOR SHOP HEAT TREATMENT

SHOP

ENGINE ERECTION SHOP

ENGINE TESTING SHOP

LOCO DIVISION

LOCO TEST SHOP LOCO

FRAME SHOP

PIPE SHOP

TRUCK MACHINE SHOPTRACTI

ON ASSEMBLY SHOP

SHEET METAL SHOP

LOCO ASEEM

BLY SHOP

LOCO PAINT SHOP

Sub Assembly ShopThis shop deals with following section:- Turbo machining section Cylinder head & shot blast section Fuel pump, support, cam shaft ate section Cylinder head Turbo Governor, Water pump, Fan Drive, Lube oil pump, After Cooler assembly section.

 

Heat Treatment Shop

In this shop hardening, stress leaving, tempering, normalizing, carburizing, quenching, is done by help of

conventional & unconventional process. Here we are doing hardening of cam-shaft, connecting rod, piston

pin, different small components of cylinder head.

This shop is divided in two parts which are as follows:-

Induction Section- Use for induction hardening

Furnace Section- Use for overall process

Loco Assembly ShopL.A.S. Operation:- Drive cap assembly, Air compressor assembly, Control stand assembly. Driver cap checking, Air brake piping. Long hood assembly, Buffer assembly, Radiator setting. Engine setting, Compressor setting. Long hood setting, Auxiliary generator assembly and setting Alternator part packing and assembly. Equipment assembly, Fuel oil parking, Lube oil piping, Engine water cooling piping. Driver sheet setting, Damper assembly, Air, duct setting.

Engine Erection ShopEngine erection shop There are seven sections in this shop from 01 to 07 action have two or three station as given below:- • Station No. 1 to 4 in section 01.• Station No. 5, 6, 6A and 6B are in section 02 to 03.• Station No. 7 to 12 are in section 04 to 07.• Station No.1 to 4 - Washing, debarring and panting.• Station No. 5 - Cam shaft bush fitting cylinder head stud driving linear Sleeve and Liner pressing and

water testing. • Station No. 6A - Piston Assembly.• Station No.6B - Crank Shaft Assembly.• Station No 6 - Piston Assembly Heads, Exhaust Manifold, water Connection, Air elbows, Nozzle and

water header Pipe-fitting.• Station No.7 to 9 - Lowering engine block, oil catcher, Generator, Lube Pump and water pump fitting oil• Station No. 10 - Cam shafts, gears, Control shaft, Turbo supper cooler, Oil Seal, Turbo super charger

application.• Station No.11 & 12 - Fuel pump Support, Valve leaver, Governor

THANK YOU !