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A technical traning report on INDIAN RAILWAYS TECHNICAL TRAINING CRNTRE DIESEL LOCOMOTIVE WORKS Varanasi 221004

summer training report on dlw varansi

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Page 1: summer training report on dlw varansi

A technical traning report on

INDIAN RAILWAYSTECHNICAL TRAINING CRNTRE

DIESEL LOCOMOTIVE WORKS Varanasi 221004

Page 2: summer training report on dlw varansi

GAUTAM BUDHA TECHNICAL UNIVERSITY, LUCKNOW, INDIA

2011-12

BACHELOR OF TECHNOLOGYdegree

In

MECHANICAL ENGINEERING

submittedby

AMIT KUMAR CHAUHANto

Mr. Y.S.RAJPUT(LECTURERE OF DEPARTMENT)

COLLEGE OF ENGINEERING&

RURAL TECHNOLOGYMEERUT

Page 3: summer training report on dlw varansi

TABLE OF CONTENTS

1. Acknowledgment2. Preface3. Introduction 4. Brief History5. Product EMD WDP46. Manufacturing Process Engine Division Vehicle Division Block Devision7. Workshops LMS ET TMS LAS8. Orginizational Strength9. Our Quality Policy10. Environmental/ Societal Orientation

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ACKNOWLEDGEMENT

I owe a great many thanks to a great many people who helped and

supported me during making of this reporte.

My deepest thanks to Lecturer, Mr.Y.S.Rajput the Guide of the

reporte for guiding and correcting various documents of mine with

attention and care.

I express my thanks to the Lecturer Mr.D.P.Singh & HOD of

departement, Dr.B.K.Singh, for extending his support.

My deep sense of gratitude to Traning incharge Mr.S.K.Singh

support and guidance. Thanks and appreciation to the helpful people for

their support.

I would also thank my Institution and my faculty members without

whom this reporte would have been a distant reality. I also extend my

heartfelt thanks to my family and well wishers.

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PREFACE

The objectives of the practical training are to learn

something about industries practically and to be familiar with

the working style of a technical person to adjust si mply

according to the industrial environment.

It is rightly said practical life is far away from theoretical

one We learn in class roo m can give the practical exposure or

real life experience no doubt they help in i mproving the

personality o f the , b ut the practical exposure in the field will

help the st udent in long run o f life and will be ab le to

imp lement the theoretical knowledge.

As, a part o f academic syllabus of four year degree

course in Mechanical Engineering every student is required to

undergo a practical training.

I am st udent of third year mechanical and this report is

written on the basis of practical knowled ge acquired by me d uring

the period on the basis of practical knowled ge acquired by me d

uring the period of practical training taken at Diesel Locomotive

Works, Varanasi.

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INTRODUCTION

Diesel Locomotive Wo rks (DLW) is production unit under the

ministry of railways. This was setup in collaboration with American

locomo tive co mpany (ALCO) USA in 19 61 and the first locomotive

was rolled out in 196 4. This unit produces diesel electro nic locomotives

and DG sets for Indian railways and ot her customers in India and

Abroad.

Subseq uent ly a contract for transfer of techno lo gy of 4000 HP

Microprocessor Controlled AC/AC Freight (GT 46 MAC) / passenger

(GT 46 PAC) locomot ives and family of 71 0 engines has been signed

with electro motive divisio n of general mo tors of USA for manufacture

in DLW. the prod uction of these loco motives has now started and thus

DLW is the only manufacturers of Diesel Electric Locomo tives wit h

both ALCO and General motors technologies in the world.

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Brief History

The Diesel Locomotive Works (DLW) in Varanasi, India, is a

production unit owned by Indian Railways, for which it manufactures

diesel-electriclocomotives and spare parts.

Founded in 1961, the DLW rolled out its first locomotive three

years later, on January 3, 1964. It manufactures locomotives which are

variants based on the original ALCO designs dating to 1960s and

the GM EMD designs of the 1990s. DLW has an annual production

capacity of 150 locomotives and plans to increase it to 200 based on the

current demand.

DLW locomotives have power outputs ranging from 2,600

horsepower (1,900 kW) to 4,000 horsepower (3,000 kW). Currently

DLW is producing EMD GT46MAC and EMD GT46PAC locomotives

under license from Electro-Motive Diesels (formerly GM-EMD) for

Indian Railways.

Varanasi, one of the oldest populated cities in the world and has a

promising place in the international ground both as a hub of traditions

and technology. One side the humming of divine and holy bells of the

temples brings the city to life; on other side Diesel Locomotive Works

(DLW) Varanasi is one of the largest industrial unit in eastern part of the

nation. DLW catch the attention of lot of foreign tourist students to

observer on going amazing locomotive manufacturing process in

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Varanasi. Diesel Locomotive works Varanasi is located at the North end

of the city and about 8 Km away from the Holy River Ganges Ghats.

DLW is an ISO 9002, ISO 14001 & OHS 18001 Certified Organisation .

Diesel Locomotive Works, Varanasi (DLW) is one of the main

manufacturing units run by the Indian Railways. This manufacturing

unit came into existence in year 1961, as a “Green Field Project” in

industrial association with ALCO, USA. This unit generate all the Diesel

Electric Locomotives. In year 1964, the first locomotive was

manufactured and it was devoted to the country. Diesel Locomotive

Works, Varanasi produces only Electric Diesel locomotives and

auxiliary parts of locomotives. However it is an Indian corporation but it

has supplied locomotives to some foreign countries also, includes

Angola, Bangladesh, Malaysia, Myanmar, Sri Lanka, Vietnam and

Tanzania.Engine section manufacture more than 2000 machinery, which

comprise ALCO turbo superchargers, cylinder heads, connecting rods,

camshafts, lubricating oil pumps, chrome plated cylinder liners and

Vehicle section of DLW unit works on different fields that include

Currently, Diesel Locomotive Works, Varanasi constructs locomotives

and DG sets. In locomotives section, again it manufactures two different

types of products, one is EMD and another is ALCO. 

MILE STONES

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August 1961

DLW set up as a green field project in technical collaboration with ALCO, USA for manufacture of Diesel Electric Locomotives

January 1964

First Locomotive rolled out and dedicated to the Nation

January 1976

Entered Export market, first locomotive exported to Tanzania

December

1977

First Diesel Generating Set commissioned

October 1995

The Transfer of Technology agreement was  signed

March 2002

The first indigenous EMD WDG4 freight loco manufactured

November

2002

3600 HP Engine produced

March 2003

The first indigenous passenger version of EMD loco WDP4 manufactured

September

2003

Development of 16 cylinder 3300 HP Power upgraded DLW engine, WDM3D  locomotive

2006   5000th locomotive produced

November

2006

DLW manufactured first WDG4 locomotive equipped with IGBT based converter

March 2007

First WDP4 locomotive equipped with IGBT based converter

April 2007

DLW has successfully switched over to use of microprocessor based control system on all its locomotives.

March 2009

257 locomotives manufactured in 2008-09, highest ever locomotive production

November

2009

5690 locomotives upto 30th Nov’2009(including 348 EMD locos)

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PRODUCT

EMD

WDG4 - 4000 HP GOODS LOCOMOTIVE

Broad Gauge freight traffic Co-Co diesel electric locomotive

with 16 Cylinder 4000 HP engine, AC-AC transmission,

microprocessor controlled propulsion and braking with high traction

First turned out in 1999 with transfer of technology from General

Motor (USA), this locomotive has exceptional fuel efficiency and

very low maintenance requirements. It is specifically designed for

heavy haul freight traffic requirements of Indian Railways for the 21st

Century.

  The heart of loco Traction Control Converter uses the GTO

devices (obsolete technology). Now the IGBT devices, has been

introduced from Oct?2006. It is the latest technology and will be cost

effective. .

The locomotive power has been upgraded to 4500 BCV and the

first Loco (Loco No 12114) was manufactured in May?07 

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Diesel Engine Transmission

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 ? 950 Lts

Electrical AC-AC

6 Traction motor ( 3 in parallel per

bogie)

Suspension ? Axle hung / taper

roller bearing

Gear Ratio ? 90:17

 

 

Truck Brakes

High adhesion HTSC

( High Tensile Steel Cast) truck of bogie

Adhesion ? 0.42

Electronic Air Brake

System ( KNORR-NYAB-Computer

Controlled Braking)

Air , hand , dynamic brake

Pure air brake

 

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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

21 T

1676 mm

Co-Co

1092 mm

4201 mm

3127 mm

19964 mm

126 T

54 T

100 Kmph

6000 lts

EM 2000 with SIBAS-

16 Traction Control

WDG4-4000 HP TRACTIVE

Page 13: summer training report on dlw varansi

GOODS LOCOMOTIVEEFFORT & POWER

CHART

WDP4

4000 HP PASSENGER LOCOMOTIVE

State-of-Art, Microprocessor controlled AC-AC, Passenger

Locomotive Powered with 16-710G3B 4000HP Turbo charged Two

stroke engine.

Fabricated rigid design Under frame, two stage suspension,

High Traction High Speed 3 axle (HTSC) light weight cast truck frame

attribute to high adhesion performance. 

First turned out in 2003, this locomotive has exceptional fuel

efficiency and very low maintenance requirements. It is specifically

designed for heavy haul passenger traffic requirements for Indian

Railways. 

The WDP4 fleet is being upgraded by provision of hotel load

feature along with power upgradation to 4500 HP. The prototype will

be manufactured in the year 2007.

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Diesel Engine Transmission

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 ? 1073

Lts

Electrical AC-AC

4 Traction motor ( 3 in parallel

per bogie)

Suspension ? Axle hung / taper

roller bearing

Gear Ratio ? 77:17

 

Truck Brakes

High adhesion HTSC ( High

Tensile Steel Cast) truck or bogie

Adhesion ? 0.42

Electronic Air Brake

System ( KNORR-NYAB-Computer

Controlled Braking)

Air , hand , dynamic brake

with fully blended with automatic brakes

Pure air brake

 

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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

 

WDP4-4000 HP GOODS

LOCOMOTIVE

TRACTIVE EFFORT

& POWER CHART

Page 16: summer training report on dlw varansi

1. ALCO

1350 HP CAPE GAUGE LOCOMOTIVE

VDM 4

TECHNICAL INFORMATION

1350 HP Locomotive having fabricated cape gauge Co-Co

bogie. hese locomotives have been supplied to Angola and Sudan.

Wheel

Arrangement

Co – Co

Track

Gauge

1067 mm Cape

gauge

Weight 72 t

Overall

Length

15600 mm

Wheel

Diameter

921 mm

Gear Ratio 18: 93

Maximum 90 Kmph

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Speed

Diesel

Engine

Type : ALCO 251 D

6 Cyl. in line.

HP 1350

Transmissio

n

Electrical AC/DC

Brake 28LAV-1 system

Loco Air, dynamic,

parking

Train Air & Vacuum

Fuel Tank

Capacity

3000 Litres

Page 18: summer training report on dlw varansi

2300 HP CAPE GAUGE LOCOMOTIVE

TECHNICAL INFORMATION

2300 HP 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 1067 mm Cape

Gauge

Weight 102 t

Overall

Length

17620 mm

Wheel

Diameter

921 mm

Page 19: summer training report on dlw varansi

Gear Ratio 18 : 93

Maximum

Speed

100 Kmph

Diesel Engine Type : ALCO 251-B 12

Cyl. V- Engine

HP 2300

Transmission Electrical AC/DC

Brake IRAB-1

Loco Air, Dynamic, parking

Train Air

2300 HP METER GAUGE LOCOMOTIVE

TECHNICAL INFORMATION

2300 HP 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

Co-Co

Track Gauge 1000 mm Meter Gauge

Weight 102 t

Overall 17620 mm

Page 20: summer training report on dlw varansi

Length

Wheel

Diameter

921 mm

Gear Ratio 18 : 93

Maximum

Speed

100 Kmph

Diesel

Engine

Type : ALCO 251-B 12

Cyl. V- Engine

HP 2300

Transmissio

n

Electrical AC/DC

Brake IRAB-1

Loco Air, Dynamic, parking

Train Air

Fuel Tank

Capacity

3000 Litres

3000 HP CAPE GAUGE LOCOMOTIVE

TECHNICAL INFORMATION

( Provisional Specifications)

3000 HP Micro Processor Controlled, Main Line, Cape Gauge

Locomotive with improved Cab, under development for Mozambique

Page 21: summer training report on dlw varansi

Railway.

Wheel

Arrangement

Co-Co

Track Gauge 1067 mm Cape Gauge

Weight 114 t

Overall

Length

18632 mm

Wheel

Diameter

1000 mm

Gear Ratio 19 : 92

Maximum

Speed

100 Kmph

Diesel

Engine

Type : ALCO 251-C 16

Cyl. V- Engine

HP 3000

Transmissio

n

Electrical AC/DC

Brake IRAB-1

Loco Air, Dynamic

Train Air

Fuel Tank

Capacity

6000 Litres

1350 HP METER GAUGE LOCOMOTIVE 

YDM4

Page 22: summer training report on dlw varansi

TECHNICAL INFORMATION

 

1350 HP Locomotive having cast / fabricated meter Gauge Co-

Co bogie. Such locomotives have been supplied to Vietnam and

Myanmar. 

Wheel

Arrangement

Co – Co

Track Gauge 1000 mm

Weight 72 t

Overall

Length

15600 mm

Wheel

Diameter

965 mm

Gear Ratio 18: 93

Maximum

Speed

96 Kmph

Diesel

Engine

ALCO  251 D 6 Cyl. in 

line.

HP 1350

Transmissio

n

Electrical AC/DC

Brake IRAB ? 1 system /

28LAV-1

Page 23: summer training report on dlw varansi

Loco Air, dynamic, parking

Train Air / Dual (Air and

Vacuum)

Fuel Tank

Capacity

3000 Litres

 

 

BROAD GAUGE MAIN LINE FREIGHT LOCOMOTIVE

WDG 3A

TECHNICAL INFORMATION

Page 24: summer training report on dlw varansi

Diesel Electric main line, heavy duty goods service locomotive,

with 16 cylinder ALCO engine and AC/DC traction with micro

processor controls.

Wheel

Arrangement

Co-Co

Track Gauge 1676 mm

Weight 123 t

Length over

Buffers

19132 mm

Wheel Diameter 1092 mm

Gear Ratio 18 : 74

Min radius of

Curvature

117 m

Maximum Speed 105 Kmph

Diesel Engine Type : 251

B,16 Cyl.- V

HP 3100

Brake IRAB-1

Loco Air, Dynamic

Train Air

Fuel Tank

Capacity

6000 litres

BROAD GAUGE MAIN LINE MIXED SERVICE

LOCOMOTIVE

WDM 3D

Page 25: summer training report on dlw varansi

TECHNICAL INFORMATION

Diesel Electric Locomotive with micro processor control

suitable for main line mixed Service train operation.

Wheel

Arrangement

Co-Co

Track Gauge 1676 mm

Weight 117 t

Max. Axle

Load

19.5 t

Length over

Buffer

18650 mm

Wheel

Diameter

1092 mm

Gear Ratio 18 : 65

Maximum

Speed

120 Kmph

Diesel

Engine

Type : 251 B-16 Cyl. ?V?

type (uprated)

HP 3300 HP (standard UIC

condition)

Transmissio Electric AC / DC

Page 26: summer training report on dlw varansi

n

Brake IRAB-1 system

Loco Air, Dynamic, Hand

Train Air

Fuel Tank

Capacity

5000 litres

BROAD GAUGE SHUNTING LOCOMOTIVE

WDS 6AD

Page 27: summer training report on dlw varansi

TECHNICAL INFORMATION

A heavy duty shunting Diesel Electric Locomotive for main line

and branch line train operation. This locomotive is very popular with

Steel Plants and Port Trusts.

Wheel

Arrangement

Co-Co

Track Gauge 1676 mm

Weight 113 t

Length over

Buffer

17370 mm

Wheel

Diameter

1092 mm

Gear Ratio 74 : 18

Maximum

Speed

50 Kmph

Diesel

Engine

Type : 251 D-6 Cyl. in-

line

HP 1350 / 1120 HP (std.)

MANUFACTURING PROCESS

Engine Division

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COMPONENT MACHINING

Over 2000 components are manufactured in-house at DLW. These include ALCO turbo superchargers, lubricating oil pumps, cam shafts, cylinder heads, chrome plated cylinder liners, connecting rods and various gears. Our well-equipped Machine Shops have dedicated lines for operations like turning, milling, gear

hobbling, drilling, grinding and planning etc. 

In addition, DLW is equipped with a variety of special purpose machines and a large number of state-of-the-art CNC machines to ensure quality and precision.

Associated manufacturing processes like heat treatment and induction hardening are also carried out in-house.

A completely new Chrome Plating Shop for Cylinder Liners has been set up with modern infrastructure like fume extraction system and Programmable Logic Controlled material movement system.

Engine Assembly & Testing

Pre-inspected engine block, crankshaft, camshafts, cylinder liners, pistons, connecting rods, cylinder heads, exhaust manifold, turbo-supercharger and all related piping is used in assembly of engine.

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Electrical machines like traction alternator, auxiliary generator and exciter are thereafter coupled on the engine. 

The complete power pack with electrics are tested on Computerised Engine Test Beds to verify horsepower output. Vital parameters of engine are checked to assure the quality of product. 

Only after the engine parameters are found perfect the power packs are cleared for application on locomotives.

Vehicle Division

Component Fabrication

Precision cutting and forming of sheet metal is utilised for manufacture of superstructures including drivers cab, engine hoods, and compartments for housing electrical equipment. All activities connected with pipes like pickling, bending, cutting, forming and threading of pipes of various sizes are undertaken in another well-equipped work area. 

All electrical equipment is assembled in the fabricated control compartments and driver?s control stands is done in another work area.

 

Under frame Fabrication

Under-frames are fabricated with due care to ensure designed weld strength. Requisite camber to the under-frame is provided

Page 30: summer training report on dlw varansi

during fabrication itself. Critical Welds areas are tested radio-graphically. Welder training and their technical competence are periodically reviewed. EMD under-frame is fabricated using heavy fixtures, positioners to ensure down hand welding.

Fixtures are used to ensure proper fitting of components and quality welding in subsequent stages.

BOGIE MANUFACTURING

Special purpose machines are utilised for machining cast and fabricated bogie frames. Axle and wheel disc machining is undertaken on sophisticated CNC machines. Inner diameter of wheel discs are matched with the outer diameter of axles and assembled on wheel press. The complete truck (bogie), including bogie frames, wheels and axles, brake rigging and traction motors are assembled which is ready for application to locomotive.

LOCOMOTIVE ASSEMBLY

Tested engines are received from Engine Division. Similarly under-frames are received from Loco frame Shop and Assembled trucks from Truck Machine Shop. Superstructures and contractor compartments are received from respective manufacturing and assembly shops of Vehicle Division. Important alignments like crank shaft deflection, compressor

alignment and Eddy Current clutch/radiator fan alignment are done during assembly stage. 

Electrical control equipments are fitted and control cable harnessing is undertaken. The complete locomotive is thus assembled before being sent onwards for final testing and painting.all locomotive systems are rigorous tested as per laid down test

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procedures before the locomotive is taken up for final painting and dispatch.

Block Division

Flame Cutting of Components

Steel plates are ultrasonically tested before being precision cut by numerically controlled flame cutting machines, Plasma Cutting Machine. Components are straightened and machined prior to fitting & tacking on fixture designed specially for engine block fabrication to ensure close tolerance on engine block.

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. High quality of welding is done by qualified welders. Weld joints are subjected to various

tests like ultrasonic, X-rays, Visual etc. 

Down-hand welding is ensured using specially designed positioners.

Fabrication of engine block is completed by submerged arc welding using semi-automatic welding machines. Special fixtures are used for making down-hand welding possible in inaccessible areas. Critical welds are subjected to radiographic examination. All welders are periodically tested and re-qualified for the assigned.

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After complete welding weldment is stress relieved and marking is done for subsequent machining. 

Portal Milling Machine

Engine block machining is done on Portal Milling Machine which is a 5 axis CNC machine with SIEMENs 840-D state of art system control with dedicated tool management system. This machine performs milling, drilling,

tapping and boring operations in single setting. 

The machine accuracy of 10 micron enables adhering to the tolerance required on engine block.

Angular Boring Machine

Angular boring "V" boring is done of special purpose machine. This special purpose machine has two high precision angular boring bars.  

WORKSHOP

Light Machine Workshop(LMS)Engine Testing(ET)Truck Machine Shop(TMS)Loco Assembly Shop(LAS)

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This shop deals with the matching of vario us small co mpo nents

required fo r the power pack unit such as, cam shaft, co nnecting rod,

liners, gears levers, F.P. Support, Piston pin, nuts and bo lts bushes,

various shafts etc.

The light machine shop divided into the following section:- Econometric section Grinding section Gear section Cam shaft sect ion A.T.L. section Belching section Connect ing rod section Lathe section Liners section Drilling section Milling section

Organizational Strength

A flagship production unit of Indian Railways offering complete range of products in its area of operation with annual turnover of over 2124 Crore.

State of the art Design and Manufacturing facility to manufacture

.

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200 locomotives per annum with wide range of related products viz. DG Sets, Loco components and sub-assemblies.

Supply of spares required to maintain Diesel Locomotives and DG sets.

Unbeatable trail-blazing track record in providing cost-effective, eco-friendly and reliable solutions to ever increasing transportation needs for over four decades.

Fully geared to meet specific transportation needs by putting Price - Value - Technology equation perfectly right.

A large base of delighted customers among many countries viz. Myanmar, Sri Lanka, Malaysia, Vietnam, Bangladesh, Tanzania, Angola, to name a few, bearing testimony to product leadership in its category.

Our Quality Policy

Quality, Environment, Health & Safety Policy

Diesel Locomotive Works is a Production Unit of Indian Railways, manufacturing Diesel-electric Locomotives, Diesel Generating sets and their spares for Indian Railways, Non-Railway Customers and exports.

We are committed to achieve excellence by:

Continual improvement of the Quality, Environmental and Health & Safety - at- work - place performance.

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Preventing pollution by all means including minimizing resource consumption and waste generation using cleaner technologies, material substitution and process changes.

Preventing all injuries and loss of property including environmental performance through continuous safety inspections.

Striving for compliance with all applicable Environmental and Health & Safety legislations.

Striving for "Right first time" and safe working practice through system improvement and training.

Enhancing Customer Satisfaction through improvement in reliability and performance of products.

Preventing all employees from occupational diseases and health hazards.

We shall:

Set objectives & targets and periodically monitor their progress through internal audit and management review.

Communicate Quality, Environment and Health & Safety policy to the employees and to make it available to the public on demand.

Environmental/Societal Orientation

Environmental Management 

A healthy and congenial environment alone can produce and promote healthy citizens we firmly believe. In order to have a clean and green

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DLW, we have a well defined integrated environmental policy. This promotes an ever motivated work-force, giving rise to products of International standard.

   

Environmental Objectives: Reduction in Resourceconsumption Reduction in Fire Emergencies -10% every year Improvement in Emergency preparedness Monitoring of water & ambient air periodically

Sewage Treatment Plant: 

STP is mainly concerned with the treatment of domestic and industrial sewage. The treated water is used for irrigation purpose up to nearby Lohta farm and kitchen gardening at DLW premises.The digested sludge is sent to sludge drying beds, later to be used as manure. Methane gas mainly produced from the

digester is collected in the gas holder and supplied to the canteen. 

Industrial Effluent Treatment Plant:

IETP does the job of treatment of industrial effluent which mainly contains oil and grease . The treated water is sent to nearby villages for farming and kitchen gardening at DLW. 

Chromium Treatment Plant:

CTP deals with the treatment of effluents from CRP shop (Chrome Plating Shop). This has varying concentration of hexavalent chromium.

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This hexavalent chromium is converted into trivalent chromium in acidic condition and is precipitated. This sludge, after drying in the form of cakes,  is stored in a covered tank made of concrete. Water after treatment is used for irrigation in nearby villages.

Occupational Health & Safety Management:

DLW is OHSAS-18001 certified since September, 2005. OHSAS formulates the work-procedures, defines hazards, assesses the risks involved therein and generates awareness regarding use of personal protective equipments at workplace. This enhances safety at work-place, reduces chances of accidents and makes workers more confident leading to increase in productivity.

OHS Objectives: Reduction in HOD cases -10% every year Improvement in use of PPEs (100%) Recharging of Ground water