TRAINING AT DLW VANARASIPresented By..Enter Your NameMechanical EngineeringEnter Roll Number
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introductioN DLW was founded by 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 late, on January 3, 1964. It manufactures locomotives.
INTRODUCTIONDLW IS A production unit under the ministry of railway, it is one of the factories in the world which can be called diesel locomotive manufacturing plant .It had made over 2000 component s are manufactured.
Set up in 1961 technical collaboration with ALCO of USA for manufacture of diesel electric locomotive .
In 1995 , Indian railway entered into an agreement with general motors ,USA is transfer this technology for manufacture of 4000hp microprocessor controller.
INTRODUCTIONGot its first ISO certification in 1997 and ISO-9001 and ISO-14001 in December 2002.
At present the locomotive produced by DLW; i.e. GM engine has capacity up to 5000HP & try to make it 5500 HP.
It has supplied locomotive to other countries such as Sri lanka , Bangladesh , Malaysia, Vietnam etc.
DLW is supplied locos to PSUs & Industries like NTPC , coal , INDOGULF etc.
SOME FACTS ABOUT DIESEL ELECTRIC LOCOMOTIVEDLWS annul Production -275Component are manufacture -2000 component Cost of one LOCO -25 crore(EMD) -15 crore (ALCO)Weight of one LOCO -121 tonFuel consumption at full load -540 lit/hr Fuel consumption at idle load -40 lit/hr Max. Speed -160km/hrDia. of wheel -1092mm
SOME FACTS ABOUT DIESEL ELECTRIC LOCOMOTIVE
Alco engine assembly
GM ENGINE ASSEMBLY
PRODUCTION SHOPSBLOCK DIVISIONSENGINE DIVISIONSLOCO DIVISIONS
BLOCK DIVISIONS Heavy Weld ShopHeavy Machine Shop
Engine Division1.Engine Erection Shop2. Engine Testing Shop3. Light Machine Shop4. Sub Assembly Shop5. Rotor Shop6. Heat Treatment Shop7. Turbo Section
LOCO DIVISIONLoco Frame ShopPipe ShopTruck Machine ShopTraction assembly ShopSheet Metal ShopLoco Assembly ShopLoco assembly ShopLoco Paint ShopLoco test Shop
Types of Welding used in DLWShielded Metal Arc Welding (SMAW)Submerged Arc Welding (SAW)Gas Shielded Metal Arc Welding (MIG)Flux Cored Arc Welding (FCAW)
Rotor shopThis shop is deals with the manufacturing of Turbocharger. Turbocharger is known as the Heart of Diesel Locomotive. Basically in this section manufacturing of assembly & sub assembly of Turbocharger is made. But the outer casing of Turbocharger is made up in Heavy Machine Shop.Turbocharger is use for the providing fresh air to the engine. Due to this the efficiency & power generated by engine is increased. For the running of Turbocharger we are not using any extra energy source like generator, motor etc. For starting of Turbocharger generally we use exhaust gasses.
Components of TurbochargerFor assembly of Turbojet following parts are manufactures in rotor shop---1. Impeller 2. Inducer 3. Nose piece 4. Stud Rotor 5. Nut 6. Washer 7. Thrust Washer 8. Key 9. Oil Slinger
Assembly of Turbocharger:-- The assembly of turbocharger is done by dividing whole turbocharger in three parts. These are as follows---- 1. Rotor 2. Compressor 3. Casing 1. Rotor:-- Rotor is the inlet part of turbocharger which is comprises with following parts. Turbo Disc, Rotor stud, Turbo shaft, thrust collar, Nose disc, Washer & Nut. Rotor is rotating at speed of 18000 rpm & working at high temperature due to that the rotor is made of steel.
2. Compressor:-- Compressor is the combination of impeller & inducer. Impeller is made up of Al-alloy. Impeller & inducer is use for sucking of fresh air from environment.3. Casing:-- Casing is made of M.S. & also a special type of coating is done. Due to that coating it can easily resist the heat. For the proper working & life of Turbocharger balancing of impeller, inducer & turbine disc is done by help of Dynamics Balancing Machine
Traction motor Since the diesel- locomotive uses electric transmission , traction motors are provided on the axles to give the final drive .These motors were traditionally DC but the development of the modern power and control electronics has led to the introduction of 3 AC motors.
This is part (called the bogie in the UK) carrying the wheels and traction motors of the locomotive
ANGULAR BORING MACHINE
LOCO & ENGINE TEST SHOP
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.
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 testingFor 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.
Engine test operation sequenceCheck 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.
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.