dlw training report, varanasi

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ISO 9001:14001 Certified

TRAINING REPORT D. L. W.(Diesel Locomotive Works)

SUBMITTED BY

VIVEKANAND PANDEY 3rd B.TECH 3 YEAR MECHANICAL ENGINEERING

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TABLE OF CONTENTS:1. 2. 3. 4. 5. 6. 6. 7. Acknowledgment Preface Introduction of D.L.W. Brief History Product EMD WDP4 Manufacturing Process Engine Division Vehicle Division Block Division Workshops Heavy Weld Shop Light Machine Shop Engine Testing T.M.S. Organizational Strength

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Conclusion

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I would sincerely like to thank the employees & the officers of DLW, Varanasi for their help & support during the vocational training. Despite their busy schedules, they took time out for us & explained to us the various aspects of the working of the plant, from the production shops. I expressed my thanks to the lecturer Mr. D.P. Singh & HOD of department, Dr. B.K. Singh for extending his support. I would also thank my institution & my faculty members without whom this report would have been a distant reality. I also extend my heartfelt thanks to my family & well wishers.

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PREFACEThe objectives of the practical training are to learn something about industries practically & to be familiar with the working style of technical person to adjust simply according to the industrial environment. It rightly said practically life is far away from theoretical one. We learn in class room can give the practical exposure or real life experience no doubt they help in improving the personality of the student, but the practical exposure in the field will help the student in long run of life & will be able to implement the theoretical knowledge. As a part of academic syllabus of four year degree course in Mechanical Engineering .Every student is required to undergo a practical training. I am student of Third year mechanical & this report is written on the basis of practical knowledge acquired by me during the period of practical training taken at Diesel Locomotive Work, Varanasi

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INTRODUCTIONDiesel Locomotive Works is production unit under the ministry of railway. This was setup in collaboration with American locomotive company (ALCO) USA in 1961 & the first locomotive was rolled out in 1964. This unit products diesel electronic locomotive & DG sets for Indian railways & other customers in India Abroad. Subsequently a contract for transfer of technology of 4000HP Microprocessor Controlled AC/AC Freight (GT 46 MAC) / passenger (GT 46 PAC) locomotive & family of 710 engines has been signed with electromotive division of GM of USA for mfg in DLW is the only mfg of Diesel Electric locomotive with both ALCO & GM technologies in the world.

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BRIEF HISTORYThe Diesel Locomotive Works (DLW) in Varanasi India is a production unit owned by Indian Railways, for which it manufactures diesel-electric locomotives & spare parts.August 1961DLW set as a green field project in technical collaboration with ALCO, USA for manufacture of Diesel Electro Locomotive. First Locomotive rolled out & dedicated to the Nation. Entered Export market, first locomotive exported to Tanzania. First Diesel Generating Set commissioned The Transfer of technology agreement was signed. The first indigenous EMD WDG4 freight locos manufacturing. 3600 HP Engine manufactured The first indigenous passenger version of EMD loco WDG4 manufactured Development of 16 cylinder 330 HP power upgraded DLW engine, WDM3D locomotive DLW manufactured first DG4 locomotive equipped with IGBT based convertor First WDP4 locomotive equipped with IGBT based convertor. DLW has successfully switched over to use of microprocessor based control system on all its locomotives. 257 locomotives manufactured in 20082009, highest ever locomotive production. 5690 locomotives up to 30th Nov 2009(including 348 EMD locos).

January January December October March November March September November March April March November

1964 1976 1977 1995 2002 2002 2003 2003 2006 2007 2007 2009 2009

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Types of LOCOMOTIVES PRODUCTION at DLWThe first letter (gauge) 1. W- Indian broad gauge( The W stands for wide Gauge-5ft) 2. Y- meter gauge( The Y stands for Yard guage-3ft) 3. Z- narrow gauge(2ft 6 inch) 4. N- narrow gauge(2ft) The second latter (motive power) 1. D- Diesel 2. C- DC electric (can run under DC traction only) 3. A- AC electric (can run under AC traction only) 4. CA-Both DC & AC (can run under both AC & DC tractions) 5. B- Battery electric locomotive (rare) The third letter (job type) 1. G- goods 2. P- passenger 3. M-mixed; both goods & passenger 4. S-Used for shunting (also known as switching engines or switchers in United States & some other countries) 5. U-Electric multiple units (used as commuters in city suburbs) 6. R-Railcars Ex: - WDM3A:W- broad gauge D- diesel motive M- suitable for mixed service 3A- The locomotives power is 3100HP Or, WAP5: W- broad gauge A- AC electric traction motive power P- suitable for passenger 5- denote that this locomotive is chronologically the 5th electric locomotive model Used by the railway for passenger service.

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DIESEL TRACTION ASSEMBLY AT DLW

EMDWDG4- 4000 HP GOODS LOCOMOTIVE

(WDG4 LOCOMOTIVE) Diesel Engine 16 cylinder

(TRACTION EFFORT & POWER CHART) Transmission Electrical Ac-Ac 6 Traction motor (3in parallel per bogie) Suspension? Axle hung/taper roller bearing. Gear Ratio 90:17

710G3B, 2 turbocharger. After cooled.

stroke,

Fuel Efficient Engine Injection System? direct Unit Injector Governor? Woodward Compression Ratio 16:1 Lube Oil Sump Capacity 950Lts Truck Brakes High adhesion HTSC (High Tensile ElectronicSteel Cast)truck of bogie Adhesion 0.42

Air Brake System(KNORRNYAB-Computer Controlled Braking) Air, hand, dynamic brake Pure air brake 4000HP 21 T 1676mm Co-Co 1092mm 4201mm 3127mm 19964mm 126 T 54 T 100Kmph 6000Lts EM 2000 Control with SBIAS-16 Traction

General Characteristic Installed Power Axle Load Gauge Wheel arrangement Wheel diameter Height Width Overall Length(Over Buffer Beam) Weight Max tractive effort Maximum speed Fuel tank capacity Locomotive control

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WDP4- 4000HP PASSENGER LOCOMOTIVE

Diesel Engine 16 Cylinder 710 G3B, 2 stroke, turbocharged after cooled Fuel Efficient Engine Injection System Direct Unit Injector Governor Woodward Compression Ratio- 16:1 Lube Oil Sump Capacity 1073Lts Truck High adhesion HTSC ( High Tensile Steel Cast) truck or bogie Adhesion 0.42

Transmission Electrical AC-AC 4 Traction motor ( 3 in parallel per bogie) Suspension Axle hung / taper roller bearing Gear Ratio 77:17

BrakesElectronic Air Brake System ( KNORR-NYAB-Computer Controlled Braking) Air , hand , dynamic brake with fully blended with automatic brakes Pure air brake

General Characteristic Installed Power Axle Load Gauge Wheel arrangement Wheel diameter Height Width Overall Length (Over Buffer Beam) Weight Max tractive effort Maximum speed Fuel tank capacity Locomotive Control 4000 HP 19.5 T 1676 mm A-A-I I-A-A 1092 mm 4201mm 3127 mm 19964 mm 117 T 27 T 160 Kmph 4000 lts EM 2000 with SIBAS-16 Traction Control

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ALCO:-

1350 HP CAPE GAUGE LOCOMOTIVE VDM4

TECHNICAL INFORMATION

1350 HP Locomotive having fabricated cape gauge Co-Co bogie. hese locomotives have been supplied to Angola and Sudan.Wheel Arrangement Track Gauge Weight Overall Length Wheel Diameter Gear Ratio Maximum Speed Diesel Engine HP Transmission Brake Loco Train Fuel Tank Capacity Co Co 1067 mm Cape gauge 72 t 15600 mm 921 mm 18: 93 90 Kmph Type: ALCO 251 D 6Cyl. In line. 1350 Electrical AC/DC 28LAV-1 system Air, dynamic, parking Air & Vacuum 3000Litres

2300 HP CAPE GAUGE LOCOMOTIVE

TECHNICAL INFORMATION 2300HP Main Line Locomotive, having fabricated cape gauge Co-Co bogies. These are provided with two drivers cabs, one at each end. These locomotives have been supplied to Angola and Sudan. Wheel Arrangement Co-Co Track Gauge Weight Overall Length 1067 mm Cape Gauge 102 t 17620 mm

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Wheel Diameter Gear Ratio Maximum Speed Diesel Engine HP Transmission Brake Loco Train Fuel Tank Capacity

921 mm 18 : 93 100Kmph Type: ALCO 251-B 12Cyl. V- Engine 2300 Electrical AC/DC IRAB-1 Air, Dynamic, parking Air 3000Litres

2300 HP METER GAUGE LOCOMOTIVE

TECHNICAL INFORMATION

2300HP Main Line Locomotive, having fabricated meter gauge Co-Co bogies. These are provided with two drivers cabs, one at each end. These locos have been supplied to Malaysia, Senegal and Mali.Wheel Arrangement Track Gauge Weight Overall Length Wheel Diameter Gear Ratio Maximum Speed Diesel Engine HP Transmission Brake Loco Train Fuel Tank Capacity Co-Co 1000 mm Meter Gauge 102 t 17620 mm 921 mm 18 : 93 100Kmph Type: ALCO 251-B 12Cyl. V- Engine 2300 Electrical AC/DC IRAB-1 Air, Dynamic, parking Air 3000Litres

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3000 HP CAPE GAUGE LOCOMOTIVE

TECHNICAL INFORMATION (Provisional Specifications)

3000HP Micro Processor Controlled, Main Line, Cape Gauge Locomotive with improved Cab, under development for Mozambique RailwayWheel Arrangement Track Gauge Weight Overall Length Wheel Diameter Gear Ratio Maximum Speed Diesel Engine HP Transmission Brake Loco Train Fuel Tank Capacity Co-Co 1067 mm Cape Gauge 114 t 18632 mm 1000 mm 19 : 92 100Kmph Type: ALCO 251-C 16Cyl. V- Engine 3000 Electrical AC/DC IRAB-1 Air, Dynamic Air 6000Litres

1350 HP METER GAUGE LOCOMOTIVE YDM4

TECHNICAL INFORMATION

1350HP Locomotive having cast / fabricated meter Gauge Co-Co bogie . Such locomotives have been supplied to Vietnam and Myanmar.Wheel Arrangement Track Gauge Weight Overall Length Wheel Diameter Gear Ratio Ma