Summer Training Presentation, DLW Varanasi

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  1. 1. Summer training report on dieSel locomotive workS varanaSi
  2. 2. SHAILESH SHUKLA CT-1674/09 MECHANICAL ENGINEERING CAET, ETAWAH
  3. 3. introduction DLW, was founded by Late 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 dieselelectric 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 later, on January 3, 1964. It manufactures locomotives.
  4. 4. Got its first ISO certification in 1997 and ISO-9001 and ISO-14001 in December 2002. With technology transfer agreement from manufacturers such as GM-EMD, DLW today produces advance locomotives having output range from 2600 to 4000 hp. At present the latest locomotive produced by DLW; i.e. WDG 5 has capacity upto 5000 HP & trying to make it 5500 HP. It has supplied locomotives to other countries such as Sri Lanka, Bangladesh, Malaysia, Tanzania and Vietnam etc. DLW is supplying locos to PSUs & Industries Like NTPC, COAL, INDOGULF etc.
  5. 5. Some factS about dieSel electric locomotive DLWs 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. Dia of Wheel - 1092 mm Wheel to Wheel Distance - 1596.5 mm Length of Under Frame - 19962 mm
  6. 6. dieSel electric locomotive In 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.
  7. 7. claSSification of locomotiveS Locos, except the older steam ones, have classification codes that identify them. This code is of the form WDG5A [ gauge ][ power ][load ][ series ][ sub type ] the firSt letter (gauge) W- Indian broad gauge Y- meter gauge Z- narrow gauge(2.5 ft) N- narrow gauge (2 ft) the Second letter (motive power) D- Diesel C- DC electric (can run under DC traction only) A- AC electric (can run under AC traction only) CA- Both DC and AC (can run under both AC and DC tractions) B- Battery electric locomotive (rare)
  8. 8. the third letter (load type) G-goods P-passenger M-mixed traffic ; both goods and passenger S-Used for shunting U-Electric multiple units (E.M.U.) R-Railcars 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 3000 hp but less than 4000 hp. the fifth letter (Subtype) an optional letter or number that indicates some smaller variations in the basic model. For ex: A for 100 hp, B for 200 hp and so on..
  9. 9. 1. block diviSionS 2. engine diviSionS 3. loco diviSionS production ShopS block diviSion 1. Heavy Weld Shop 2. Heavy Machine Shop
  10. 10. engine diviSion 1. Engine Erection Shop 2. Engine Testing Shop 3. Light Machine Shop 4. Sub Assembly Shop 5. Rotor Shop 6. Heat Treatment Shop 7. Turbo Section
  11. 11. loco diviSion 1. Loco Frame Shop 2. Pipe Shop 3. Truck Machine Shop 4. Traction Assembly Shop 5. Sheet Metal Shop 6. Loco Assembly Shop 7. Loco Paint Shop 8. Loco Test Shop
  12. 12. welding Shop Welding is a process which produces joining of materials by heating them to suitable temperatures with or without the application of pressure and with or without the use of filler material. Welding is used for making permanent joints. It is used in the manufacturing of automobile bodies, aircraft frames, railway wagons, machine frames, structural works, tanks, furniture, boilers, general repair work and ship building.
  13. 13. Shielded Metal Arc Welding [SMAW] Submerged Arc Welding [SAW] Gas Shielded Metal Arc Welding [MIG] Flux Cored Arc Welding [FCAW] Shielded Metal Arc Welding [SMAW] Submerged Arc Welding [SAW] Gas Shielded Metal Arc Welding [MIG] Flux Cored Arc Welding [FCAW] typeS of welding uSed in dlwtypeS of welding uSed in dlw
  14. 14. What is sMaW?What is sMaW? It is a welding process which joins metals by heating the metals to their melting point with an electric arc set up between the end of a coated metal electrode and the work piece. Molten metal droplets and the molten weld are shielded from the atmosphere by the gases produced from the decomposition of the flux coating .
  15. 15. Advantages of SMAWAdvantages of SMAW Equipment used is simple, inexpensive. Electrode provides and regulates its own Flux. This process has excellent suitability for outdoor use lower sensitivity to wind and even for use under water. All position capability Equipment used is simple, inexpensive. Electrode provides and regulates its own Flux. This process has excellent suitability for outdoor use lower sensitivity to wind and even for use under water. All position capability 08/30/13 Build the nation with welding 15
  16. 16. saW Process PrinciPles SAW is a welding process which joins metals by heating the metals to their melting point with an electric arc or arcs set up between a bare metal electrode and the job. The arc, the end of electrode and molten pool remains completely hidden and are invisible being submerged under a blanket of granular flux. The continuously fed bare metal electrode melts and acts as filler rod.
  17. 17. SAW Features High Productivity, high amperages may be used Easy to de-slag High Quality Deep penetration Excellent mechanical properties Environment friendly Very little fume No radiation Easy operation High Productivity, high amperages may be used Easy to de-slag High Quality Deep penetration Excellent mechanical properties Environment friendly Very little fume No radiation Easy operation
  18. 18. GMaW Gas Metal Arc Welding is a welding process which joins metals by heating the metals to their melting point with an electric arc, produced between continuous consumable electrode wire and the metal being welded. Wire is fed continuously and automatically from a spool through the welding gun Shielding gases include inert gases such as argon and helium for copper and aluminum welding, and active gases such as CO2 for steel welding Bare electrode wire plus shielding gases eliminate slag on weld bead. No need for Applications: Used for C, Si, Cu, Ni, Ti etc. For welding tool steels and dies. For the manufacture of refrigerator parts.
  19. 19. Gas Metal Arc ( MIG ) Welding Uses continuous wire 0.6 2.0 mm as electrode Gas shielded, inert or active gas Manual, automatic or semi- automatic process High productivity If the wire feed speed is increased more current is drawn to burn it off . Increasing the current increases the arc energy and therefore the heat input. This in turn increases fusion and penetration, wire deposition rate and travel speed.
  20. 20. FCAW Process Features Uses tubular wire with flux inside Gas shielded (FCAW-G) or self shielded (FCAW-S) The flux produces a protective slag and/or gas cover High productivity process with low spatter. Smooth arc with CO2. Argon mixtures give superior performance Problem of high fumes which need to be extracted in enclosed areas
  21. 21. 22 laser cUttinG-UPto 4MM
  22. 22. 23 UnDer Water PlasMa cUttinG UPto 16 MM
  23. 23. boGie asseMbly shoP A bogie is a wheeled wagon or trolley. In mechanics terms, a bogie is a chassis or framework carrying wheels, attached to a vehicle. Usually the train floor is at a level above the bogies, but the floor of the car may be lower between bogies.
  24. 24. boGie asseMbly (eMD) Wheel and Axle assembly. Brake rigging assembly. Traction motor & gear case assembly. Bearing adopter assembly. Final assembly.
  25. 25. Axle, Wheel & Axle Box AssemBly These wheels are having wear adapted profile to RDSO drawing.
  26. 26. Dead Lever Live Lever Cylinder Lever Brake Shoe Brake Head BrAke rigging ArrAngement
  27. 27. Axle, Wheel & geAr AssemBly With trAction motor
  28. 28. trAction motor Electric motor providing the primary rotational torque of a machine, usually for conversion into linear motion. DC series-wound motors, running on approximately 600 volts. The availability of high-powered semiconductors such as thyristors has now made practical the use of much simpler, higher- reliability AC induction motors.
  29. 29. JournAl BeArings & AdAptor The bogie frame is supported on axles through soft primary suspension consisting of twelve single helical coil springs, two springs mounted on each bearing adapter (axle box), to provide ride quality and equalization of wheel-set loads. Bearing adapter are fitted with tapered roller pre-lubricated, pre adjusted & sealed bearings. Bearing adapter single helical coil springs Sealed bearings TPU shims
  30. 30. AssemBly process: PRESS BULL GEAR ON AXLE. SHIFT ABOVE ASSEMBLY AT BEARING HOUSING FITTING STAND. FIT THE BEARING HOUSING AND BOLTING . ASSEMBLE SEAL , CAP AND TAPER ROLLER BEARING BOLTING . NOW, SHIFT THIS ASSEMBLY ON WHEEL & AXLE PRESS MACHINE.
  31. 31. BreAkdoWn mAintenAnce Break down of machine can occur due to the following two reasons: Due to unpredictable failure of component which cannot be prevented. 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 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. mAintAinAnce AreA
  32. 32. oBJective of preventive mAintenAnce To obtain maxim