VOCATIONAL TRAINING

REPORT
DIESEL LOCOMOTIVE WORKS
VARANASI

BY
SHASHANK SHARMA
12EMHME401
 ACKNOWLEDGEMENT

I would sincerely like to thank the employees and the

officers of DLW, VARANASI for their help and support

during the vocational training. Despite their busy

schedules, they took time out for us and explained to us

the various aspects of the working of the plant, from the

production shops.

DLW VARANASI 2
 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 simply according to the industrial environment.

As, a part of academic syllabus of four year degree course in

Mechanical Engineering, every student is required to undergo a
practical training.

I am student of Final Year Mechanical from MAIIT,KOTA-Rajasthan Technical

University and this report is written on the basis of practical knowledge acquired
by me during the period of practical training taken at Diesel Locomotive Works,
Varanasi .

DLW VARANASI 3
 INTRODUCTION

Diesel Locomotive Works (DLW) is production unit

under the ministry of railways. This was setup in collaboration
with
American locomotive company (ALCO) USA in 1961 and the
first
locomotive was rolled out in 1964. This unit produces diesel
electronic
locomotives and DG sets for Indian railways and other
customers in India
and Abroad.

DLW VARANASI 4
 INTRODUCTION

Subsequently a contract for transfer of technology of 4000 HP

Microprocessor Controlled AC/AC Freight (GT 46 MAC) /
passenger
(GT 46 PAC) locomotives and family of 710 engines has been
signed
with electro motive division of general motors of USA for
manufacture
in DLW. the production of these locomotives has now started
and thus
DLW is the only manufacturers of Diesel Electric Locomotives
with both
ALCO and General motors technologies in the world.

DLW VARANASI 5
 PRODUCT OF DLW

DLW is an integrated plant and its manufacturing facilities are

flexible in
nature. these can be utilized for manufacture of different
design of
locomotives of various gauges suiting costomer requirments
and other
products. the product range avilable is as under.

DLW VARANASI 6
 PRODUCTS OF DLW

WDG4 4000 HP AC/AC Frieght traffic Locomotive

WDP4 4000 HPAC/AC Broad Gauge High Speed

Locomotive

WDG3D 3400 HP AC/AC Broad Gauge Mixed Traffic

Micro-Processor Controlled Locomotive.

WDM3C 3300 HP AC/DC Broad Broad Gauge Mixed

Traffic Locomotive.

WDM3A 3100 HP AC/DC Broad Gauge Mixed Traffic

Locomotive.

WDP3A 3100 HP AC/DC Broad Gauge High Speed

Passenger Locomotive.
DLW VARANASI 7
 WORKSHOPS
These are the workshops in DLW plant.
i. HWS ii. HMS iii. LMS iv.
ROTOR
v. HTS vi. SAS vii. EES viii. ET
ix. LFS x. SMS xi. TMS xii. PS
xiii. LTS xiv.LPS xv. TR xvi.TAS
xvii. MA-I xviii.MA-II xix.MA-II xx.MA-II
xxi.MSS xxii.MRS xxiii.CMT LAB xxiv. ELECT.LAB

These all work in coordination in the overall fabrication of engine and

then finally locomotive.

DLW VARANASI 8
 ALLOTED WORKSHOP
• I was alloted the following workshop to perform my
vocational training.

1) LMS---Light Machine shop.

2) ROTOR----Rotor shop.
3) TMS------Traction Machine shop.
4) MSS------Maintenance Service shop.
5) MA-1-------Maintenance Area-1
6) PIPE SHOP
The following slides deals with what I have learnt during
My training in these workshop.

DLW VARANASI 9
 FLAME CUTTING OR OXYGEN CUTTING

• Requires that the part to be cut be raised to a temperature

of 1,500-1,600ºF
• Stream of pure oxygen directed onto hot metal causing it to
burn rapidly
• Burning steel gives off iron oxide as a product of
combustion
• Iron oxide solid at room temperature
• Melting point below melting point of steel so iron oxide runs
off as molten slag, exposing more iron to jet

DLW VARANASI 10
 BASIC PRINCIPLE

Around this center hole are a number

of preheating flame holes

Cutting tips may be obtained in

various shapes and sizes. The
thicker the metal that is to be cut,
the larger the size of the center hole
must be.

The cutting tip has a central hole through

which the high pressure oxygen flows.
DLW VARANASI 11
 STANDARD CUTTING TIPS

The standard tip has a straight bore cutting

oxygen port and is typically used with oxygen
pressures in the 30 to 60 p.s.i. range.

DLW VARANASI 12
 MULTIPLE CUTTING TORCHES

A number of cutting torches

are mounted on the machine
so that a number of parts of
the same shape can be cut
simultaneously. These
machines can be used for
straight-line or circle
cutting.
They can be guided by hand
or a template.

DLW VARANASI 13
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.
 Bogie Assembly (EMD)

 Wheel and Axle assembly.

 Brake rigging assembly.
 Traction motor & gear case assembly.
 Bearing adopter assembly.
 Final assembly.
 Axle, Wheel & Axle Box assembly

These wheels are having wear adapted profile to RDSO drawing.

Axle, wheel & Gear assembly with
Traction Motor
Brake Rigging Arrangement

Live Lever Cylinder Lever

Dead Lever

Brake Shoe

Brake Head
 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.

Sealed bearings

TPU shims

Bearing adapter

single helical coil springs

 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.
 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.
 MAINTAINANCE AREA
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.
 objective of preventive maintenance

 To obtain maximum availability of the plant by avoiding break down and by

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.

 MACHINE SHOP

1. Heavy Machine Shop

2. Light Machine Shop
 Types of machines
1. Conventional machine
2. NC machine
3. CNC machine

1. Conventional machine:
It is a simple machine which is now an old technique.

2. Numerical control machine:

Numerical control is defined as a system in which the actions of the machines are
controlled by the insertion of the numerical data. In other words number
controls the action.
 Classification of numeric control

1. Point to point system:

This feature is only useful for drilling and boring
operations. The machine operations are possible at specified positions.

2. Straight line system:

In this system the control can command a path operation
in a single axis at a time.

3. Continuous path system:

In this system the control instructs the machine to
make movements like 2 or 3 axis at a time. The machine may be directed to
make helical or circular path.
 Computerized numerically controlled
machine
• In CNC the control system further energized with a mini computer or a post
processor.

• The control unit stores the programmed information of the work piece, the
travel limits, collisions zones and the diagnostic information etc. it also
gives a feedback to the operator about the current position and distance to
be travelled etc.

• CNC machines have the ability to edit or alter the existing program in no
time.
 machines in area B
Flame cutting CNC Laser cutting
• The laser beam is typically
0.2 mm (0.008 in) diameter
at the cutting surface with a
power of 1000 to 2000 watts.
• Lasers work best on
materials such as carbon
Steel plates are ultrasonically steel or stainless steels
tested before being precision cut because these are difficult
by numerically controlled flame to cut due to their ability to
cutting machines or by CNC reflect the light as well as
LASER machine. absorb and conduct heat.
This requires lasers that are
more powerful.
 Angular Boring Machine
• This special purpose machine has
two high precision angular boring
bars.
• Boring bars are mounted on high
precision bearings which provide
control on size during angular
boring.
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
 ROTOR SHOP
• This shop deals with the maufacturing of turbocharger.

• Turbocharger is known as the heart of diesel

locomotive. Basically in this section manufacturing of
assembly and subassembly of turbocharger is being
made. But the outer casing is made in heavy machine
shop.
• Turbocharger is used for providing fresh air to
the locomotive.

DLW VARANASI 30
 ROTOR SHOP –CONT.

• Due to this power and efficiency of engine is improved.

• For the running of turbocharger we are not using any

extra energy resources generator , motor etc. for
starting of turbocharger we generally use exhaust
gases.

DLW VARANASI 31
 ROTOR SHOP-CONT.

• Components of turbocharger.

• For assembly of turbojet following parts are manufactured 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
10. Turbine disc
11. Turboshaft
12. Lockplate

DLW VARANASI 32
 ROTOR SHOP –CONT

• 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

DLW VARANASI 33
 ROTOR SHOP-CONT

• 1. Rotor:--

 Rotor is the inlet part of turbocharger which is comprises

with following parts. TurboDisc, 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.

DLW VARANASI 34
 ROTOR-SHOP-CONT

• 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.

DLW VARANASI 35
 ROTOR SHOP-CONT

• Working of turbocharger-

• Exhaust gasses are entering form inlet strikes onto the

nozzle disc. Then it will strike onto the turbine blade. Due to
this the turbine starts rotating at a speed from 0-18000rpm.
It will transfer the motion to compressor which is
comprises with impeller & inducer. From that rotation
sucking of fresh air from environment is
occurring. That air is now entered in intermediate casing
and blow from blower casing.

DLW VARANASI 36
 SCHEMATIC

DLW VARANASI 37
 TURBOCHARGER

SCHEMATIC

DLW VARANASI 38
 TURBOCHARGER

SCHEMATIC

DLW VARANASI 39
 ROTORSHOP-CONT

• The various machine tools installed in ROTOR SHOP are

i. CNC turning centre--(twin spindle)---MW/no 3544

operations---
Turning,groving,boring,drilling,milling,taper
turning.
---here it is being used for machining valve
bridge.
beside above---
a.)linerslip
b.)spindle

DLW VARANASI 40
 ROTORSHOP-CONT

• Features:-

Since there is specific programme for each machining

operations, it is used for mass productions
with less variations.
Also machining time is lesser and it is fastly replacing
the manually operated machines.

ii. Vertical turret lathe machine----1973

This is being used for machining for “Retainer cylinder head”

iii. Horizontal milling and boring machine.

iv. Radial drilling and tapping machine.

DLW VARANASI 41
v. CNC horizontal machining centre.

vi. Press brake system.

------These CNC,NC,MANUAL-operated machines

manufacture all the items described above.

DLW VARANASI 42
 LOCOMOTIVE FRAME SHOP
• Under frame Fabrication:

--- Under frames are fabricated with due care to ensure

designed weld strength. Requisite
camber to the under frame is provided during fabrication itself.
Critical welds are tested
radio-graphically.

DLW VARANASI 43
 LFS--SHOP

DLW VARANASI 44
 FABRICATION-WORK

DLW VARANASI 45
 LFS--SHOP

 Welder training and their technical competence are

periodically reviewed. High Horse
Power (HHP) 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.

DLW VARANASI 46
 LFS--SHOP

DLW VARANASI 47
 NOMENCLATURE

OF DIESEL LOCOMOTIVE
• 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)

DLW VARANASI 48
 NOMENCLATURE-CONT

• 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), 'CA' is considered a single letter

• B-Battery electric locomotive (rare)

DLW VARANASI 49
 NOMENCLATURE--CONT
• 1. G-goods
• 2. P-passenger
• 3. M-mixed; both goods and passenger
• 4. 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

DLW VARANASI 50
 NOMENCLATURE--CONT
• The fourth letter (horse power)

• For example, in "WDM 3A":

• "W" means broad gauge
• "D" means diesel motive power
• "M" means suitable for mixed(for both goods and
passenger)service
• "3A" means the locomotive's power is 3,100 HP ('3' stands
for 3000 HP, 'A' denotes
• 100 HP more)

DLW VARANASI 51
 ENGINES AT DLW
• There are two type of engine

• EMD (Electro motive Division)

• ALCO (American Locomotive)

• EMD is two stroke diesel engines and ALCO is four stroke

diesel engines.
• Turbocharger end is known as turbo or alternator or rear
end and governor and accessories is known as accessory or
governor or front end.

DLW VARANASI 52
 ENGINES AT DLW

• EMD engine is known as HHP (high Horse Power) or GM

(general motor). EMD engine has maximum power is 4500
HP and ALCO engine has maximum Power is 3300 HP.

DLW VARANASI 53
THANKS