INSTITUTE OF ENGINEERING & TECHNOLOGY

SUBMITTED BY:AMIT KUMARIV YEARIET, ALWAR

SUBMITTED TO:PROF. AMIT MALIKHOD, MECHANICALIET, ALWAR

A REPORT onTRAINING(INDUSTRIAL)

TRAINING

On

DIESEL LOCOMOTIVE WORK, VARANASI (A production unit of Loco owned by Indian Railways)

From 22 May to 2 July 2015

INTRODUCTION DIESEL LOCOMOTIVE WORKS (DLW), Varanasi (India) an

ISO 9001:14001 & OHS 18001 certified production unit owned by Indian Railways, it is a central unit of Govt. of India (ministry of Railway).

It was laying of foundation stone of factory by the first president of India Late Dr. Rajendra Prasad in 1956 & Diesel Locomotive Works came existence in 1961.

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

First locomotive rolled out and dedicated to nation in January, 1964.

Got its first ISO certification in 1997 and ISO-9001 and ISO-14001 in December 2002.

State of the art Design and manufacturing facility to manufacture 200 locomotive per annum with wide range of related products viz. DG Sets , Loco components and sub-assemblies.

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

At present the latest locomotive produced by DLW; i.e. WDG 5 has capacity upto 5000 HP & trying to make it 5500 HP.

First loco realesed by late lal bahadur sastri in 1964 ,WDM2

SALIENT FEATURES:

Annual production capacity 200 LocomotiveAnnual turn-over(Rs) 5000 millionTotal number of staff 8223Workshop land 219.997 acreTownship area 520.6 acreCovered area in shops 30.37 acre Covered area of other service buildings 19.13 acre Water consumption 223.82 Lakh Litres/dayElectrical Energy Consumption 262.07 Lakh Unit / YearWorkshop 4200 KVAAdministrative Building 1500 KWStand by Power Generation Capacity 5625 KW

some facts about diesel electric locomotive

DLW’s annual production -250 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. Running speed on track -110-20 km/hr Dia of Wheel - 1092 mm(OD) Wheel to Wheel Distance - 1596.5 mm Length of Under Frame - 19962 mm

Integrated Quality, Environment, Health and Safety Policy:

Product of DLW:

1.WDG5 5500 HP AC/AC Freight operation type locomotive2. WDG4 4000 HP AC/AC Freight Traffic Locomotive3. WDP4 4000 HPAC/AC Broad Gauge High Speed4. WDG3D 3400 HP AC/AC Broad Gauge Mixed Traffic Micro-Processor Controlled Locomotive.5. WDP3A 3100 HP AC/DC Broad Gauge High Speed passenger Locomotive6. WDM2 2600 HP AC/DC Broad Gauge Mixed Traffic Locomotive7. YDM4 1350 HP AC/DC &DC/DC Broad Gauge Mixed Locomotive 8. WDP4D 4400 HP ac/ac Broad Gauge High Speed Locomotive

General information about some locomotive product (WDG4):

Installed Power 4000HP

 

Axle Load 21T

 

Gauge 1676mm

 

Wheel arrangement Co-Co

Wheel diameter 1092mm

Height 4201mm

Width 3137mm

Overall Length (Over Buffer Beam) 19964m

Weight 126T

Max tractive effort 54T

Maximum speed 100kmph

Fuel tank capacity 6000lts

Locomotive Control EM 2000 with SIBAS 16 Traction Control

Gear Ratio 90:17

Besides the Indian Railway, it regularly exports diesel electric locomotive and has supplied locomotives to other countries such as Sri Lanka, Malaysia, Bangladesh, Mali, Senegal, Sudan, Tanzania, Angola, Mozambique and Vietnam and also to a few users within India, such as ports, large power and steel plants and private railways.

List of locomotive supplied to Non Railway Customers;1. SAIL2. VSP3. NTPC4. SEB & OTHERS

MRAKETING STATERGY:-

Diesel electric locomotiveIn 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.

In India, locomotives are classified according to their track gauge, motive power, the work they are suited for and their power or model number. The class name includes this information about the locomotive.it comprises 4 and 5 letters.

Classification of locomotives

Classification of locos on the basis of code form

WDG5A “ [ gauge ][ power ][load ][ series ][ sub type ]”

In the first letter [Gauge]:W-Indian Broad Gauge (5.6ft)

Y-Meter Gauge or Yard Gauge (the "Y" stands 3ft or 1000mm)

Z-Narrow Gauge (2.5ft)

N-Narrow Gauge or Toy Gauge (2ft)

In the second letter [Power]:D-Diesel

C-DC Traction (can run under DC traction only)

A-AC Traction (can run under AC traction only)

CA-Both DC and AC (can run under both AC and DC tractions)

B-Battery Electric Motive (rare)In the third letter [Load]:G-goods

P-passenger

M-mixed Traffic (both goods and passenger)

S-Used for Shunting

U-Electric multiple units (EMU)

R-Railcars

In 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 3000hp but less than 4000hp.

In the fifth letter [subtype]:An optional letter or number that indicates some smaller variations in the basic model.For ex: ‘A’ for 100hp, ‘B’ for 200hp and so on……..Example: Designation of ‘WDM-3A’ mean"W" means broad gauge "D" means diesel motive power "M" means suitable for both goods and passenger service"3A" means the locomotive's power is 3,100 hp('3'stands for 3000hp ’’A' denotes 100hp more)

WDG5 Preliminary Locomotive Layout:

Specification:Fuel tank capacity - 7500ltsWeight - 133.8tonLength - 22.3mWheel arrangement - co-coGear ratio - 90:21

Production Shops

BLOCK DIVISION

ENGINE DIVISION

LOCO DIVISION

BLOCK DIVISION:

i. Heavy Weld Shop

ii. Heavy Machine Shop

Engine Divisions:i. Light Machine Shop

ii. Engine Erection Shop

iii. Engine Testing Shop

iv. Sub Assembly Shop

v. Rotor Shop

vi. Heat Treatment Shop

Loco Divisions:

i. Loco Frame Shop

ii. Pipe Shop

iii. Truck Machine Shop

iv. Sheet Metal Shop

v. Traction Assembly Shop

vi. Loco Assembly Shop

vii. Loco Test Shop

viii. Loco Paint Shop

Production Flow Chart:

Marking out

Cutting To Size

CAD/

CAM

Machine And

Machining Process

cutting

Joint

Assembly

Testing And

Evaluation

CHEMICAL & METALLURGICAL TESTING LABChemical & Metallurgical Testing is domain of material science and engineering that studies the physical and chemical behaviour of metallic elements, and their intermetallic compounds and their mixture before used in manufacturing process define/calculate its various properties via testing for good quality & safety purpose.

In DLW, Testing Lab is divided in various section like that chemical, physical, metallography section etc.

Basic Properties of metal:i. Physical propertiesii. Mechanical propertiesiii. Chemical propertiesiv. And properties like Thermal, Electrical, Magnetic

ENGINE ERACTION SHOPEngine eraction shop (EES) is part of Engine Division. In EES, Eraction means built engine with assembly different-different items of engine, In these under shop deals with different items parts assembly and different items of engine.In under shop two types Engine eracted;1. ALCO 2. GM

DEBURRING, WASHING & PAINT SECTIONPISTON CRANK SHAFT & CYLINDER ERACTION PISTON CRANK SHAFT & CYLINDER HEAD ERACTIONGENERATOR CAMSHAFT CONTROL SHAFT &

APPLICATIONFUEL PUMP & VALVE LEVERS

ERACTION SHOP OF GM

PRODUCTION PLANNING AND CONTROL OFFICEProduction control is the task of predicting, planning and scheduling work, taking into Account manpower, material availability and other capacity restrictions, and cost so as to achieve proper quality and quantity at time it is needed and then following up the schedule to see that the plan is carried out, using whatever systems have proven satisfactory for the purpose.

Production And Planning Control Function:-i. Planningii. Routingiii. Loadingiv. Schedulingv. Combing Functionvi. Dispatchingvii. Reporting or Follow –up.viii. Corrective Actionix. Inspection

MAINTENANCE AREAMaintenance is the action associated with equipment repair after it is broken. Also maintenance as follows” the work of keeping something in proper condition ;upkeep.” This would imply that maintenance should be action taken to prevent a device or component from failing or to repair normal equipment degradation experienced with the operation of the device to keep it in proper working order. In DLW maintenance area divided into two section based on machine works as LMS & HMS .TYPES OF MAINTENANCE:It is basically;i. Breakdown Maintenanceii. Preventive Maintenance

Breakdown Maintenance:Breakdown maintenance is maintenance performed on equipment that has broken down. Breakdown maintenance may be either planned or it can be unplanned. Break down of machine can occur due to the following two reasons:a. Due to unpredictable failure of component which cannot be prevented.b. 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:Preventive maintenance (PM) is a fundamental, planned maintenance activity designed to improve equipment life and avoid any unplanned maintenance activity.• 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.

objective of preventive maintenance 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.

SUB ASSEMBELY SHOP (SAS/EES)Wheel and Axle assemblyBrake rigging assemblyTraction motor & gear case assembly

Axle, wheel & Gear assembly with Traction Motor

LOCO PAINT SHOPAfter the Loco (engine) is made they are sent for final work of painting. Loco painting is done by spray paint. Skilled workers are employed who can make markings take shape and size under consideration.

Fig. spray paint gun

In DLW, Loco Paint Shop is divided into different- different section, which under section different -different portion painted for a specified colours.

BODERING:Light Buiscuite, Deep Yellow colour are used for WDG4. And Dazziling white, Golden yellow colour are used for WDP4.FINISHING:Pickock Blue Colour are used for WDG4. And French Blue colour are used for WDP4. FOR TRUCK PORTION:Black paint used in both WDG4 & WDP4.

In DLW, Two types paint are used:-1. Enamel Paint2. Polyvinyle Paint

For safety purpose from dust particle used glass, rubber, builder plates,cables. And resist from dust particle, Loco is spry by EZP (EPOXY ZINC PHOSPHATE).Epoxy Surfacer:-It is a process in paint (epoxy paint) is used for fill up all the gaps properly.

Fig. paint shop

EXPORTED LOCOMOTIVE:-In DLW, Figures of some standard locomotive which is exported out of country,