REPORT ON SUMMER TRAINING AT DLW, VARANASI

By: RAKESH KUMAR ME 7th semesterDr. K N MODI UNIVERCITY,NEWAI,RAJ.

To : Pradeep SirAss. Proff. Of ME(DKNMU)

CONTENTS:- Introduction Production Unit DLW, Varanasi

Types of product Diesel Traction Assembly

Specification Of WDM& Performance Specification of WDG & Performance

Welding Shop Machine Shop

Heat Treatment Shop Engine Erection Shop Sub Assembely Shop

Conclusion

INDIAN RAILWAYS: AT A GLANCE Indian Railways (Hindi: भारतीय रेल Bhāratīya Rail),

abbreviated as IR (Hindi: भा.रे.), is a departmental undertaking of Government of India, which owns and operates most of India's rail transport. It is overseen by the Ministry of Railways of the Government of India.

Indian Railways has 113,617 kilometres (70,598 mi). of total track over a route of 63,974 kilometres (39,752 mi) and 7,083 stations. It has the world's fourth largest railway network after those of the USA , Russia and China. The railways traverse the length and breadth of the country and carry over 30 million passengers and 2.8 million tons of freight daily . It is the world's second largest commercial or utility employer, with more than 1.36 million employees  As for rolling stock, IR owns over 219,931 (freight) wagons, 51,030 coaches and 8,889 locomotives.

PRODUCTION UNITS Indian Railways manufactures much of its rolling

stock and heavy engineering components at its six manufacturing plants, called Production Units, which are managed directly by the Ministry. Popular rolling stock builders such as CLW and DLW for electric and diesel locomotives; ICF and RCF for passenger coaches are Production Units of Indian Railways. Over the years, Indian Railways has not only achieved self-sufficiency in production of rolling stock in the country but also exported rolling stock to other countries. Each of these six production units is headed by a General Manager, who also reports directly to the Railway Board. The six Production Units are:-

DIESEL LOCOMOTIVE WORKS, VARANASI Brief historyAugust 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 producedMarch

2003The first indigenous passenger version of EMD loco WDP4 manufactured

TYPES OF LOCOMOTIVES PRODUCED AT DLW

The first letter (gauge)1. W-Indian broad gauge (The "W" Stands for Wide

Gauge - 5 Feet)2. Y-metre gauge (The "Y" stands for Yard Gauge - 3 Feet)3. Z-narrow gauge(2 ft 6 in)4. N-narrow gauge (2 ft) The second letter (motive power)1. D-Diesel2. C-DC electric (can run under DC traction only)3. A-AC electric (can run under AC traction only)4. CA-Both DC and AC (can run under both AC and DC

tractions), 'CA' is considered a single letter5. B-Battery electric locomotive (rare)

The third letter (job type)1. G-goods2. P-passenger3. M-mixed; both goods and passenger4. S-Used for shunting (Also known as switching

engines or switchers in United states and some other countries)

5. U-Electric multiple units (used as commuters in city suburbs)

6. R-Railcars

For example, in "WDM 3A":1. "W" means broad gauge2. "D" means diesel motive power3. "M" means suitable for mixed(for both goods

and passenger)service4. "3A" means the locomotive's power is 3,100 hp ('3'

stands for 3000 hp, 'A' denotes 100 hp more) Or, in "WAP 5":1. "W" means broad gauge2. "A" mean AC electric traction motive power3. "P" means suitable for Passenger service4. "5" denotes that this locomotive

is chronologically the fifth electric locomotive model used by the railways for passenger service

DIESEL TRACTIONASSEMBLY AT DLW

Following types of diesel loco are being produced in the DLW:

1. WDM - Wide Diesel Mixed2. WDP - Wide Diesel Passenger3. WDG - Wide Diesel Goods4. WDS - Wide Diesel Shunter

WD

M CLASS

SPECIFICATION OF WDM CLASSPower type DieselBuilder Alco, DLWModel DL560CBuild date 1962 onwardsTotal production 2700+UIC classification Co-CoGauge 1,676 mm (5 ft 6 in)Wheel diameter 1,092 mm (3 ft 7.0 in)Wheelbase 12.834 m (42 ft 1.3 in)Length 17.12 m (56 ft 2 in)Width 2.864 m (9 ft 4.8 in)Height 4.185 m (13 ft 8.8 in)Axle load 18,800 kg (41,000 lb)

Locomotive weight 112,800 kg (249,000 lb)Fuel capacity 5,000 l (1,100 imp gal;

1,300 US gal)Prime mover ALCO 251-BEngine RPM range 400 - 1000 rpmAspiration Turbo-superchargedCylinders 16Top speed 120 km/h (75 mph)Power output 2,400 hp (1,800 kW)Factor of adhesion 0.27Disposition active

PERFORMANCE

The class WDM-2 is Indian Railways' workhorse diesel locomotive. The first units were imported fully built from the American Locomotive Company (Alco) in 1962. Since 1964, it has been manufactured in India by the Diesel Locomotive Works (DLW), Varanasi. The model name stands for broad gauge (W), diesel (D), mixed traffic (M) engine. The WDM-2 is the most common diesel locomotive of Indian Railways.

The WDM-2A is a variant of the original WDM-2. These units have been retro-fitted with air brakes, in addition to the original vacuum brakes. TheWDM-2B is a more recent locomotive, built with air brakes as original equipment. The WDM-2 locos have a maximum speed of 120 km/h (75 mph) , restricted to 100 km/h (62 mph) when run long hood forward - the gear ratio is 65:18.

WD

G CLASS

SPECIFICATION OF WDG CLASSPower type Diesel-electricBuilder EMD & DLWModel GT46PACBuild date (EMD) 2001; (DLW) 2003–

PresentTotal production (EMD) 10; (DLW) 80+ under

license (in production)AAR wheel arr. A1A-A1AGauge 5 ft 6 in (1.68 m)Trucks HTSCBogies •Bo-1-1-Bo (WDP-4)

•Co-Co (WDP-4B and WDP-4D)Fuel type diesel

Fuel capacity 6,000 litersPrime mover 16-710G3BEngine type 2-stroke dieselAspiration turbochargedDisplacement 11,360 in² (186.2 liters)Alternator TA-17-CA6ATraction motors ACCylinders V16Transmission electric; AC alternator, 1

inverter per truck, AC traction motors

Power output •4,000 hp (WDP-4)•4500 hp (WDP-4B and WDP-4D)

Locomotive brakes airTrain brakes air

PERFORMANCE The WDP-4 is capable of hauling 24 coach trains at 110-

120 km/hour. It has also been used for speed trials where it has hauled 8 coach trains at 160 km/hour.

The locomotives can be used in either direction, and frequently haul trains long hood forward, as in the picture. Newer editions with 4500hp have been produced which have been named with the sub class WDP-4B /WDP-4D which have different traction control with six traction motors and are Co-Co bogie equipped, unlike the original which has a Bo-1-1-Bo arrangement with four traction motors.

The loco is very fuel efficient and has minimal exhaust emissions due to its 2 stroke diesel engine. It is characterized by its loud horn, which can be heard for large distances around, and aircraft-like sound of its running engine.

TRAINING PERIOD Following four workshop were assigned to me

during my training period of four weeks:1. Heavy Welding Shop2. Heavy Machine Shop3. Sub Assembling shop

HEAVY WELDING SHOP In heavy welding shop steel sheets of about 75mm

are welded together. To form engine block for both ALCO and GM engines. The conventional form of manufacturing engine blocks of such enormous size would have been very uneconomical.

The three main type of welding are:1. Submerged Arc Welding (SAW)2. Shielded Metal Arc Welding (SMAW)3. Gas Metal Arc Welding (GMAW)

After welding the engine blocks are thoroughly inspected for under welding and over welding. Internal cracks are detected using NDT.

The blocks are then passed to HMS for further machining and boring of holes for cylinders or Power Pack Assembly. Generally 12 to 16 holes are bored.

HEAVY MACHINE SHOP As the name suggests in the heavy machine

shop the finished engine blocks are then machined upon to produce holes for power pack assembly.

The main machines in HMS are:1. Angular boring machine (TAL / HMT)2. CNC Portal milling ( Waldrich coburg)3. Radial Drill (max. 25 ton)4. Hydraulic press

HEAT TREATMENT SHOP All the components used in an engine are heat

treated before they are assembled. The main objective behind heat treatment is to improve the machinability and wear resistance of the components.

Some of the heat treatment used are :1. Normalizing2. Quenching3. Carburizing4. Induction hardening

NO

RM

ALIZIN

G

NORMALIZING

In this heat treatment process the material is kept at a temperature 40° to 50 above critical temperature. This done due to following reasons:

1. To remove coarse grain structure 2. To remove internal stresses3. To improve mechanical properties

QU

ENCH

ING

In the figue quenching tank is used.

QUENCHING

In quenching the material is heated to a temperature of about 815° to 900°C and then it is rapidly cooled by a mixture of water and polystyrene glycol.

The main advantage of quenching is to improve machinability, hardness and development of martensite structure. Generally all the components used in the locomotive are quenched before any other heat treatment process.

CARBURIZIN

G

In the figure a carburizing furnace is shown

CARBURIZING OR CASE HARDENING

In this process a hard surface is produced on a low carbon steel of 0.15 percent carbon. In course of process the outer layer is converted into a high carbon steel with a carbon content ranging from 0.9 to 1.2 per cent of a carbon.

The components in the carburizing process are kept in contact with carbonaceous compounds and energizer (BaCO3). Then they are kept together in a furnace for a given period of time.

The hardness depends upon the penetration of carbon, temperature and time up to which its is kept in furnace. An hour of heating produces 4000 to 5000 hardness.

The main components which are carburized in the HTS are main piston pin, rocker arm assembly, crab bolts etc.

ENGINE ERECTION SHOP

In this shop we can check engine is properly work or not, Pump use •Scavenging pump

SUB ASSEMBLY SHOP This shop deals with following section:--

Turbo machining section Cylinder head & shot blast section Fuel pump, Support, Cam shaft ate sectionCylinder head Turbo Governor, Water Pump, Fan drive, Lube oil

Pump, After cooler assembly section.

INDUCTION HARDENING

Induction hardening process is the heat treatment process in which components of high carbon percentage are hardened using high frequency ac current. Generally a p.d. of 200kv to 130kv is used.

In induction hardening process there is no change in chemical composition. The work piece is kept at a distance of 3-4 mm from the coils. The current produces a magnetic flux which produces eddy current resulting in heating.

I.H. is generally done on crankshafts who have a high percentage of carbon say about .45 to .48 percent.

CONCLUSIONDuring the Tenure I have Studied the Followings:-Types of product

Diesel Traction AssemblySpecification Of WDM& PerformanceSpecification of WDG & PerformanceWelding ShopMachine ShopHeat Treatment ShopEngine Erection ShopSub Assembely Shop

THANK YOU!!!