dlw traing report

Department of Mechanical and Automotive

Engineering

Summer Industrial Training At DLW Varanasi

Summer Training Report

Vinay Kumar Kushawaha 090106260

Department of Mechanical & Automobile Engineering

Sharda University, Greater Noida

June, 2012


Engineering



Submitted in partial fulfillment of the requirements for the degree of

BATCHELOR OF TECHNOLOGY

by



Sharda University, Greater Noida June, 2012

APPROVAL SHEET


Engineering



Submitted in partial fulfillment of the requirements for the degree of

BATCHELOR OF TECHNOLOGY

by



Sharda University, Greater Noida June, 2012

APPROVAL SHEET


Engineering

Summer training report, entitled: (Title of the project) is approved for award award of 12 credits. credits.

Examiners _________ _____________ ________ _____ _

_________ _____________ ________ _____ _

Coordinator

_________ _____________ ________ _____ _

Head of Department

_________ _____________ ________ _____ _

Date:


Engineering ACKNOWLEDGEMENT

I would like to place on record my deep sense of gratitude to (RR JHA, Principal, DLW, Varanasi, for his generous guidance, help and useful suggestions.

I express my sincere gratitude to Mr. Manoj Kumar Jha, Dept. of Mechanical and Automotive Engineering, Sharda University, Greater Noida, for his stimulating guidance, continuous encouragement and supervision throughout the course of present work.

I also wish to extend my thanks to Dr. XYZ, etc. and other colleagues for attending my seminars and for their insightful comments and constructive suggestions to improve the quality of this research work.

I am extremely thankful to Prof. G.P. Sinha, Head, Dept. of Mechanical and Automotive Engineering, Sharda University, Greater Noida, for providing me infrastructural facilities to work in, without which this work would not have been possible.

Signature of the student

TABLE OF CONTENTS


Engineering

ACKNOWLEDGEMENTS

i

ABSTRACT

ii

LIST OF TABLES

iv

LIST OF FIGURES

v

ABBREVIATIONS

vi

NOTATIONS

vii

INTRODUCTION

1

Industry… ……………………………….………………....................

2

(A brief introduction of industry) Purpose………………………………………………………………..

2

(Statement of the specific work done in the industry)

INDUSTRY/ORGANIZATION …………………………………………. .

-

(History, turnover, management, turnover, products. Break the information into suitable subtitles) SPECIFIC WORK/PROJECT …………………………………………. .

-

(Purpose, procedures, software and hardware tools, machinery used, design, inspection, maintenance, results etc. Break the information into suitable subtitles) CONCLUSION …………………………………………. .

-

(Write the outcome of your work, Break the information into suitable subtitles) REFERNCE …………………………………………. .

-

(Mention the books, and published materials used if any in a suitable format)

INTRODUCTION


Engineering

Diesel Locomotive Works (DLW) is production unit under the ministry of railways. This was setup in collaboration with American locomotive company (ALCO) USA in 19 61 and the first locomotive was rolled out in 196 4. This unit produces diesel electronic locomotives and DG sets for Indian railways and ot her customers in India and Abroad.

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 71 0 engines has been signed with electro motive division of general motors of USA for manufacture in DLW. the production of these loco motives has now started and thus DLW is the only manufacturers of Diesel Electric Locomotives wit h both ALCO and General motors technologies in the world.

Brief History

The Diesel Locomotive Works (DLW) in Varanasi, India, is a production unit owned by Indian Railways, for which it manufactures diesel-electric locomotives and spare parts. Founded in 1961, the DLW rolled out its first locomotive three years later, on January 3, 1964. It manufactures locomotives which are variants based on the original ALCO designs dating to 1960s and the GM EMD designs of the 1990s. DLW has an annual production capacity of 150 locomotives and plans to increase it to 200 based on the current demand.


Engineering DLW locomotives have power outputs ranging from 2,600 horsepower (1,900 kW) to 4,000 horsepower (3,000 kW). Currently DLW is producing EMD GT46MAC and EMD GT46PAC locomotives under license from Electro-Motive Diesels (formerly GM-EMD) for Indian Railways. Varanasi, one of the oldest populated cities in the world and has a promising place in the international ground both as a hub of traditions and technology. One side the humming of divine and holy bells of the temples brings the city to life; on other side Diesel Locomotive Works (DLW) Varanasi is one of the largest industrial unit in eastern part of the nation. DLW catch the attention of lot of foreign tourist students to observer on going amazing locomotive manufacturing process in Varanasi. Diesel Locomotive works Varanasi is located at the North end of the city and about 8 Km away from the Holy River Ganges Ghats. DLW is an ISO 9002, ISO 14001 & OHS 18001 Certified Organisation.

Diesel Locomotive Works, Varanasi (DLW) is one of the main manufacturing units run by the Indian Railways. This manufacturing unit came into existence in year 1961, as a “Green Field Project” in industrial association with ALCO, USA. This unit generate all the Diesel Electric Locomotives. In year 1964, the first locomotive was manufactured and it was devoted to the country. Diesel Locomotive Works, Varanasi produces only Electric Diesel locomotives and auxiliary parts of locomotives. However it is an Indian corporation but it has supplied locomotives to some foreign countries also, includes Angola, Bangladesh, Malaysia, Myanmar, Sri Lanka, Vietnam and Tanzania. Engine section manufacture more than 2000 machinery, which comprise ALCO turbo superchargers, cylinder heads, connecting rods, camshafts, lubricating oil pumps, chrome plated cylinder liners and Vehicle section of DLW unit works on different fields that include Currently, Diesel Locomotive Works, Varanasi constructs locomotives and DG sets. In locomotives section, again it manufactures two different types of products, one is EMD and another is ALCO.


Engineering

MILE STONES August

1961DLW set up as a green field project in technical collaboration with ALCO, USA for manufacture of Diesel Electric Locomotives

January 1964First Locomotive rolled out and dedicated to the Nation January 1976Entered Export market, first locomotive exported to Tanzania Decemb 1977First Diesel Generating Set commissioned er October 1995 The Transfer of Technology agreement was signed March

2002The first indigenous EMD WDG4 freight loco manufactured

Novemb 20023600 HP Engine produced er March The first indigenous passenger version of EMD loco WDP4 2003 manufactured Septem Development of 16 cylinder 3300 HP Power upgraded DLW engine, 2003 ber WDM3D locomotive 5000th locomotive produced

2006

Novemb DLW manufactured first WDG4 locomotive equipped with IGBT based 2006 er converter March April March

2007First WDP4 locomotive equipped with IGBT based converter DLW has successfully switched over to use of microprocessor based control system on all its locomotives. 257 locomotives manufactured in 2008-09, highest ever locomotive 2009 production 2007

Novemb 20095690 locomotives upto 30th Nov’2009(including 348 EMD locos) er


Engineering

PRODUCT •

EMD


Engineering 

WDG4 - 4000 HP GOODS LOCOMOTIVE

Broad Gauge freight traffic Co-Co diesel electric locomotive with 16 Cylinder 4000 HP engine, AC-AC transmission, microprocessor controlled propulsion and braking with high traction First turned out in 1999 with transfer of technology from General Motor (USA), this locomotive has exceptional fuel efficiency and very low maintenance requirements. It is specifically designed for heavy haul freight traffic requirements of Indian Railways for the 21st Century. The heart of loco Traction Control Converter uses the GTO devices (obsolete technology). Now the IGBT devices, has been introduced from Oct?2006. It is the latest technology and will be cost effective. . The locomotive power has been upgraded to 4500 BCV and the first Loco (Loco No 12114) was manufactured in May?07

Diesel Engine •

16 Cylinder 710 G3B, 2 stroke, turbocharged ? after

Transmission •

Electrical AC-AC

•

6 Traction motor ( 3 in parallel

cooled •

Fuel Efficient Engine

•

Injection System ? Direct Unit

per bogie) •

Suspension ? Axle hung / taper roller bearing

Injector • •

Governor ? Woodward

•

Compression Ratio- 16:1

Gear Ratio ? 90:17


Engineering

ALCO


Engineering 1350 HP CAPE GAUGE LOCOMOTIVE VDM 4

TECHNICAL INFORMATION 1350 HP Locomotive having fabricated cape gauge Co-Co bogie. hese locomotives have been supplied to Angola and Sudan. Wheel

Co – Co

Arrangement Track Gauge

1067 mm Cape gauge

Weight

72 t

Overall

15600 mm

Wheel

921 mm

Length

Diameter Gear Ratio

18: 93

Maximum

90 Kmph

Diesel

Type : ALCO 251 D

Speed

Engine

6 Cyl. in line. HP

1350

Transmissi

Electrical AC/DC

Brake

28LAV-1 system

Loco

Air, dynamic,

on


Engineering

MANUFACTURING PROCESS •

•

Engine Division

COMPONENT MACHINING

Over 2000 components are manufactured in-house at DLW. These include ALCO turbo superchargers, lubricating oil pumps, cam shafts, cylinder heads, chrome plated cylinder liners, connecting rods and various gears. Our well-equipped Machine Shops have dedicated lines for operations like turning, milling, gear hobbling, drilling, grinding and planning etc. In addition, DLW is equipped with a variety of special purpose machines and a large number of state-of-the-art CNC machines to ensure quality and precision. Associated manufacturing processes like heat treatment and induction hardening are also carried out in-house. A completely new Chrome Plating Shop for Cylinder Liners has been set up with modern infrastructure like fume extraction system and Programmable Logic Controlled material movement system.

•

Engine Assembly & Testing

Pre-inspected engine block, crankshaft, camshafts, cylinder liners, pistons, connecting rods, cylinder heads, exhaust manifold, turbo-supercharger and all related piping is used in assembly of engine. Electrical machines like traction alternator, auxiliary generator and exciter are thereafter coupled on the engine. The complete power pack with electrics are tested on


Engineering Computerised Engine Test Beds to verify horsepower output. Vital parameters of engine are checked to assure the quality of product. Only after the engine parameters are found perfect the power packs are cleared for application on locomotives.

•

•

Vehicle Division

Component Fabrication

Precision cutting and forming of sheet metal is utilised for manufacture of superstructures including drivers cab, engine hoods, and compartments for housing electrical equipment. All activities connected with pipes like pickling, bending, cutting, forming and threading of pipes of various sizes are undertaken in another well-equipped work area. All electrical equipment is assembled in the fabricated control compartments and driver?s control stands is done in another work area.

•

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 areas are tested radio-graphically. Welder training and their technical competence are periodically reviewed. EMD 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.

•

BOGIE MANUFACTURING

Special purpose machines are utilised for machining


Engineering cast and fabricated bogie frames. Axle and wheel disc machining is undertaken on sophisticated CNC machines. Inner diameter of wheel discs are matched with the outer diameter of axles and assembled on wheel press. The complete truck (bogie), including bogie frames, wheels and axles, brake rigging and traction motors are assembled which is ready for application to locomotive.

•



Block Division

Flame Cutting of Components

Steel plates are ultrasonically tested before being precision cut by numerically controlled flame cutting machines, Plasma Cutting Machine. Components are straightened and machined prior to fitting & tacking on fixture designed specially for engine block fabrication to ensure close tolerance on engine block. 

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. High quality of welding is done by qualified welders. Weld joints are subjected to various tests like ultrasonic, X-rays, Visual etc.

Down-hand welding is ensured using specially designed positioners. Fabrication of engine block is completed by submerged arc welding using semi-automatic welding machines. Special fixtures are used for making down-hand welding possible in inaccessible areas. Critical welds are subjected to radiographic examination. All welders are periodically tested and re-qualified for the assigned.


Engineering After complete welding weldment is stress relieved and marking is done for subsequent machining.



Portal Milling Machine

Engine block machining is done on Portal Milling Machine which is a 5 axis CNC machine with SIEMENs 840-D state of art system control with dedicated tool management system. This machine performs milling, drilling, tapping and boring operations in single setting. The machine accuracy of 10 micron enables adhering to the tolerance required on engine block.



Angular Boring Machine

Angular boring "V" boring is done of special purpose machine. This special purpose machine has two high precision angular boring bars.

.

WORKSHOP 

Weld Workshop



Machine Shop



Heavy Weld Shop



Loco Assembly Shop(LAS)


Engineering 

Truck Machine Shop(TMS)



Loco Fabrication Workshop(LFS)

This shop deals with the matching of

various small

components required for the power pack unit such as, cam shaft, connecting rod, liners, gears levers, F.P. Support, Piston pin, nuts and bolts bushes, various shafts etc

Organizational Strength

 

   

A flagship production unit of Indian Railways offering complete range of products in its area of operation with annual turnover of over 2124 Crore. State of the art Design and Manufacturing facility to manufacture 200 locomotives per annum with wide range of related products viz. DG Sets, Loco components and sub-assemblies. Supply of spares required to maintain Diesel Locomotives and DG sets. Unbeatable trail-blazing track record in providing cost-effective, eco-friendly and reliable solutions to ever increasing transportation needs for over four decades. Fully geared to meet specific transportation needs by putting Price - Value Technology equation perfectly right. A large base of delighted customers among many countries viz. Myanmar, Sri Lanka, Malaysia, Vietnam, Bangladesh, Tanzania, Angola, to name a few, bearing testimony to product leadership in its category.

Our Quality Policy •

Quality, Environment, Health & Safety Policy


Engineering

Diesel Locomotive Works is a Production Unit of Indian Railways, manufacturing Diesel-electric Locomotives, Diesel Generating sets and their spares for Indian Railways, Non-Railway Customers and exports.

•

We are committed to achieve excellence by:



Continual improvement of the Quality, Environmental and Health & Safety - atwork - place performance. Preventing pollution by all means including minimizing resource consumption  and waste generation using cleaner technologies, material substitution and process changes. Preventing all injuries and loss of property including environmental performance  through continuous safety inspections.  Striving for compliance with all applicable Environmental and Health & Safety legislations. Striving for "Right first time" and safe working practice through system  improvement and training. Enhancing Customer Satisfaction through improvement in reliability and  performance of products.  Preventing all employees from occupational diseases and health hazards.

•

We shall:



Set objectives & targets and periodically monitor their progress through internal audit and management review. 

Communicate Quality, Environment and Health & Safety policy to the employees and to make it available to the public on demand.

Environmental/Societal Orientation


Engineering 

Environmental Management

A healthy and congenial environment alone can produce and promote healthy citizens we firmly believe. In order to have a clean and green DLW, we have a well defined integrated environmental policy. This promotes an ever motivated work-force, giving rise to products of International standard.

 • •

Environmental Objectives: Reduction in Resource consumption Reduction in Fire Emergencies -10% every

year Improvement in Emergency preparedness Monitoring of water & ambient air periodically  Sewage Treatment Plant: • •

STP is mainly concerned with the treatment of domestic and industrial sewage. The treated water is used for irrigation purpose up to nearby Lohta farm and kitchen gardening at DLW premises.The digested sludge is sent to sludge drying beds, later to be used as manure. Methane gas mainly produced from the digester is collected in the gas holder and supplied to the canteen. 

Industrial Effluent Treatment Plant:

IETP does the job of treatment of industrial effluent which mainly contains oil and grease . The treated water is sent to nearby villages for farming and kitchen gardening at DLW.



Chromium Treatment Plant:

CTP deals with the treatment of effluents from CRP shop (Chrome Plating Shop). This has varying concentration of hexavalent chromium. This hexavalent chromium is converted into trivalent chromium in acidic condition and is precipitated. This sludge, after drying in the form of cakes, is stored in a covered tank made of concrete. Water after treatment is used for irrigation in nearby villages.


Engineering 

Occupational Health & Safety Management:

DLW is OHSAS-18001 certified since September, 2005. OHSAS formulates the work-procedures, defines hazards, assesses the risks involved therein and generates awareness regarding use of personal protective equipments at workplace. This enhances safety at work-place, reduces chances of accidents and makes workers more confident leading to increase in productivity. OHS Objectives: Reduction in HOD cases -10% every year Improvement in use of PPEs (100%) Recharging of Ground water • • •


Engineering WEEK 1:- WELDING LAB

Purpose To practice arc initiation, fabrication, and testing of a butt-weld.

Material 3/16” x 1 ½” x 2” hot rolled steel plates.

Tools and Equipment Gas Metal Arc Welder, breaker bar, vice, pliers, welder’s helmet, gloves, apron.

Safety Make sure there is proper ventilation in the area that you are welding in. Always wear a functional welding helmet while welding. Always wear a leather apron and leather gloves while welding. Long sleeved shirts are also recommended. People wearing nylon-topped shoes should wear a pair of leather spats when welding. Do not attempt to touch recently welded objects (even with gloves) until they have cooled.

Procedure 1. Ensure that the ventilation system is on. 2. Attach the ground cable to the clamp on the workbench, if it has not already been done. 3. Place a piece of scrap steel on the welding bench. 4. Adjust the controls on the welding machine to the proper settings. 5. Turn on the shielding gas supply to the welding machine. 6. After the safety of all individuals in the welding area has been checked, initiate an arc, and practice laying a short bead on the scrap metal. Remember to maintain a proper arc gap, and move the welding gun slowly, in a circular motion. 7. Practice until the weld bead looks uniform along its entire length. 8. Make a butt weld by laying two test plates side by side and laying a short bead 1 to 2 inches long on the joint between them. 9. The instructor will show you how to test the welds. 10. At this point, you have a welding project to do in order to practice your welding technique. The instructor will show you what materials are available for your project and what she/he expects. You may work together or individually.


Engineering WEEK 2:- MACHINING SHOP

The Machine Shop is staffed with three Instrument Makers, each having over 30 years experience in all areas of materials and processes related to research apparatus fabrication as well as tool & die preparation. Shop tools include:

•

•

lathes capable of turning, boring and threading (both SAE and metric) diameters ranging from 17” to small precision shafts 3 axis CNC milling centers (28” x 20” travel) coupled with CAD/CAM software for programming of intricate profile machining

•

standard Bridgeport vertical mills equipped with Proto-Trac CNC systems

•

traveling wire EDM systems

•

ram EDM system capable of burning very small holes (0.0019”) in hard to machine materials

•

Brown & Sharpe 6” x 12” surface grinder

•

Welding (TIG and MIG), soldering and brazing

•

Sheet metal forming


Engineering Week 3:- HEAVY WELD SHOP

This shop mainly deals with the fabrication of the engine block and base turbo support. The engine blockis the principal, structural member of the diesel engine. Ii is composite ell- meant with principal, structural member of the diesel engine. It is composite wellmeant with heavy plates thickness varying from 16 mm to 75 mm and steel forgives conforming to specification is 2062. The spine being the most highly stressed item as we can say spine of the cylinder block is made out of one piece bitted 5”x7” thickness confirming to is cylinder wall are built around the steel forging saddles to form the air chambers which ensure the maximum rigidity for successful fabrication of cylinder block special attention is paid to the following aspects. Inspection standard Proper material Proper electrode and flux Proper welding technique Heavy weld shop 1. Heavy weld shop has three important section. 2. Flame cutting, grinding and straightening section. 3. Cylinder block fabrication section. 4. Main base, turbo support and miscellaneous section. 5. Flame cutting, grinding and straightening section. SEQUENE OF FABRICATION OF ENGINE BLOCK 1. Set up of saddles foundation plates and spine on special fixture and weld saddles spine founded on rails. 2. Set up welding of outside cylinder wall. 3. Set up of middle dock (Tack welded) with respect to target. 4. Remove can bearing shim from saddle face. 5. Intermediate machining operation remark in middle deck and chamber at top of spline. 6. Set up of inside wall and deck welded with spline. 7. Lay out of plane height. 8. Intermediate machining operation Machine height of out side wall and inside wall with respect to marking and camber. 9. Set up of top deck (Both side) and lifter block (G.E. side only) for filament of eye bolt and tack weld. 10.All in side (8x2 Beal welds) welding in done by sub are method. 11.Back gauging of saddle to foundation rail joint. 12.Lay out for bearing. 13.Set up for cam bearing. 14.Welding of the cam bearing and saddle with foundation rail bottom side (back gauge portion)


Engineering 15.Set up of cam bearing rids and weld. 16.Say out for 8” machining. 17.Intermediate machining operation. 18.Flame cut counter of foundation plate to give relief clearance to free movement of counter with respect to crank shaft. 19.Set up of the side sheets and sub arc weld of side sheets and top deck. 20.Set up of full control compartment sheet and weld. 21.Intermediate machining operation mills both and to lay out for end plates considering total length and machining allowance. 22.Hydrostatic test of water compartment. 23.Set up of top end plates and weld. 24.Set up of top deck center and weld. 25.Stress relieving weldment. 26.Kerosene oil test for control shaft compartment. 27.Shotplast. 28.Final debarring. Note: Saddle out side and inside walls foundation rail are x ray joints.

ELECTRODE Saddle, spline and foundation plates are sledded on a rotary fixture E 6020 electrodes 6.3 mm and 5 mm of M/s A Par Pvt. Ltd. Bombay and celorex of M/s Advani or Liken capable of giving X-Ray quality joints are being used for the welding. The coating is such that a stage containing iron oxide, manganese oxide and silicon is usually produced other constituents containing the oxides of aluminum manganese of sodium are prevent to modify the slag ferromanganese in the main de-oxygen and sodium silicate is used as the binder. In most cases core wire is of remounted steel.

CARE OF ELECTRODE Saddle spline rotary fixture E-6020 electrodes 6.3 mm and 5 mm. Arc welding electrodes require special care in handling and storage to That the flux coating may retain its original strength of bonding over Long periods and give satisfactory welds on use so there electrodes are Keptin a store maintains its room temperature at least 10 to 20 c Higher then the out side temperature. When the storage atmosphere In humid the moister gets deposited in the minute pores of the flux Coating. Stocking electrodes certain directly on the floor should be Avoided as also putting too many of them once above the other because the electrodes atthe bottom may get crushed. Due to the weight above. It is good practice tostock. Electrodes shelves separately according to their sires types andbatches. FLUX: - In D.L.W. auto melt gr I flux of advance linken (P) LTD. Bombay


Engineering In used. The flux in a mixture of power of deter mined practical size and each particle in chemically basic in character these particles are not fused. the flux in heated period to use in on over at 250 c for O2 hours as moisture flux generated the hydrogen in the arc and cause cold cracks in the weld deposit and in the heat effected zero.

WIRE:-Wire used in the sub are welding is the auto melt gr. A cold copper Coated size 5m.m. with low carbon content confirming to IS 2879 Manufactured by M/S Advanilincon P. ltd. Bombay. The chemical composition of the wire in carbon 0.08% m.m. 0.46% P.0.018% S0.022%. STRESS RELIVE OF CYLINDER BLOCK . After completion of welding the cylinder block in then stress relieved at the temp. Ranging from 115 F obtating total timing 28 Hrsie. (1) Pre heat time 14 Hours. (2) Soaking time 04 Hrs and (3) Cooling time 10 Hrs in stress relative’s furnace capable to accommodate to B.G. block at a time. As the engine block in machined to very close tolerances. It is necessary that all stresses developed during the fabrication stages are completely relieved before machining. This would ensure a longer life in service without any distortion which would normally result on account of very alternating stresses that the engine block is subjected to during its service.

KEROSINE OIL TEST Check that there should not be any leakage at the bottom side of the fuel control compartment welding joint after powering kerosene oil. The engine block is then shat blasted at pneumatic compressed air a pressure of75ibs/sgu.inch. DEBURING It is to be ensured that the completes (welding) weldment is free of any spatter welding defects and sharp corrosion of important welded joint have been ground then the cylinder block is marked and handed over for machining operation to H.M.S. DESINING RECOMBINATION FOR CAMBEARING SUPPORT Earlier design of cam bearing support welded with cylinder side waits then welded with the ribs (3/4”Th welded grc) due to heavy vibration and less welding area development of cracks wire observed in the com bearingsupports. (Mainly upper portion)

To over come the problem of cracks and strengthen new design of cam bearing are welded all round with the ribs and then ribs are wide with


Engineering the side cylinder wall. Hydrostatic test Water compartment are fully filled with water and after air light covering are pressure of 75 lbs/squ inch minimum is maintained for about half on hours. It there is any leakage in welds arranged welded and water listed.

Heavy weld shop 1. Heavy weld shop ha three important sections. 2. Flame cutting, grinding and straightening section. 3. Cylinder blocks fabrication section. 4. Main base, turbo support and miscellaneous section. Flame cutting, grinding and straightening section All the flame cutting items required for the B.G. & M.G. engine for block, base & turbo support are cut in the section by flame cutting machine. For all cutting of different types of items. The different types of plates are use as per their specification and thickness. Following important items are cut here. Spline, top deck, middle deck side sheet, main base and plates top rail cross web, back, plate, centers block flanges levers etc. In grinding section above items are deslaged and ground by pneumatic. Grinder. In straighten section important items of cyl-block main base and turbo support are straightened.

WELDING PROCESS (1) Out side bottom plate, top plate, centre plate to side plate both sides an rest welding is down from bottom is top in sequence number for inside welding bottom pt, top plate and rest, from bantam to top is done. (2) In this operation the support is clamped on positioned with top plate and all the rest wadding is completed. After these gauging Is done on flange oil catcher. Then later welding is done and base is welding. The entire flame cutting items required for the B.G & M.G engine for block base& turbo support are cut in the section by flame cutting machine. For all cutting of different types of item. The different of plates are use as per their specification and thickness. Following import items are cut here.


Engineering Spline top deck, middle deck side sheet main base and plates top rail cross web, back, plate, centers block flanges levers etc. In grinding Section above items are desalted and ground by pneumatic grinder. In straighten section important items of cyl-block main base and turbo

Week 4- LOCOMOTIVE ASSEMBLY Tested engines are received from EngineDivision. Similarly under-frames are receivedfrom Loco frame Shop and Assembled trucksfrom Truck Machine Shop. Superstructures andcontractor compartments are received from

respective manufacturing and assembly shops of Vehicle Division.Important alignments like crank shaft deflection, compressoralignment and Eddy Current clutch/radiator fan alignment are doneduring assembly stage . Electrical control equipments are fitted and control cable harnessing isundertaken. The complete locomotive is thus assembled before beingsent onwards for final testing and painting.all locomotive systems are rigorous tested as per laid down testprocedures before the locomotive is taken up for final painting anddispatch

Week 5- Truck Machine Shop

In this shop they make wheel, axle. After making axle and wheel they assemble the axle and wheel. In TMS the assembled wheel, axle, bull gear, bearing cap of axle etc. • Bogie: There are two types of bogie – Co-Co bogie – Bo-Bo bogie • 1. Co-Co bogie: Co-Co bogie has three axles and six wheels. •


Engineering 2. Bo-Bo bogie: Bo-Bo bogie has two axles and four wheels. • Manufacturing of bogie: There are two of manufactured bogies

Fabricated bogie Casting bogie

Important parts of bogie: •

Bogie frame

•

Axle

•

wheels

•

Bull gear

•

Suspension tube

•

axle boxes

•

Traction motor

•

•

brake riggings items air pipe

week 6 Loco fabrication shop Cylinder block fabrication section The following components for B.G. Cylinder block assembly are required. 1. End seal 2. Side plate L.S & R.S. 3. Angle L.S. & R.S. 4. Foundation plate L.S. & R.S. 5. Saddle machined inters main bearing I no. 6. Saddle machined gen end I no. 7. Saddle machined centre main bearing I no


Engineering 8. Spline I no 9. Cylinder side wall outside L.S. & R.S. 10.Cylinder side wall inside G.S. & R.S. 11.Middle deck L.S. & R.S. 12. Cam bearing (inter, gen and & frill end ) 18 nos 13. Cam ribs 18 nos 14.Top deck L.S. & R.S. and top deck centre 15.Weld strip (gen-end) R.S. & L.S. 16.Plate ( water compt drive) 17.Frill end plate. 18.Self cont. compt L.S. & R.S. 19.End plate ( gen end) 20.Cover (cont compartment ) 21.Diaphragm 22.Lifter block ( gen end)

Sequence of Fabrication assembly Setting of saddles on the fixtures as per drawing with the foundation plat L.S. & R.S. and one spine on the top of the saddle. Tacked and weldedall these with each other burn run of the saddle with spline, clean and grindthe opening of the spline, then set and face the out side and inside walls L.S.& R.S. both sides of the saddle burn run off and clean grind of the wallopening. After that setting up the middle deck weld from bed bottom side of deck and lifter block weld 16 beets all welding as quality. Saddle to foundation plate, saddle to spline and saddle to out side wall welding is check as joints. Arc wilding done machine on the cylinder block where the welding by machine is called submerged are welding. Copper coated mild steel class IIwere with flux is used. After x-ray welding test, the assembly is sent for lay our of cam bearings inmarking section. The cambering are set up tack and weld with the cam ribsand water compartment plates. After that again x-ray text of bottom plates isdone. Then burn opening and Skelton grinding operation is done. Then sendthis block assembly in the machine section for 8 machining of side sheet. Setand weld the side sheets on the 8 machining. Weld fuel self compartment onthe positioned welding machine. Weld side sheet foundation rails. Side sheetto cam ribs. Out side wall of full self compartment. After that the blockassembly is again sent to M/C section. For end milling to maintain the lengthof the block as per marking and size. Then hydraulic water test is done at 75P.S.I. At last set up the end plates (gen and free end) both side of the block assembly, tack and then setup the top deck centre in the centre of the blockand weld it by sub are welding M/C


Engineering After complete fabrication the block is sent to H.T.S. sec. for stress relivingto 700 c then shot blasting the block and sent the machine section for finalmachining. Main base fabrication The following components are required for the assembly of main base. 1. Side sheet L.S. and R.H. 2. Pipe assembly with plates 3. Engine mount free end and gen end CH/RH 4. Rib (engine mount free end &gen.end) 5. Top rail 6. Bottom. Plate (Gen end, free end & centre) 7. Plug L.O. drain. 8. Cross web G.A. 1,2,3,4,5,6,7,8, & 9 9. Cross web auxiliary assembly 10.End plate free end & gen end. 11.Oil drain compartment. 12.Pad 13.Brass engine mount free end. 14.Brass engine mount gen end. 15.L.O. suction pipe (sub. Assembly)

Sequence of Fabrication:Setting top rails on the fixture and mach the centre of the fixture. Set the side sheet R.S. & L.S. with the cross webs to maintaining the width of 31 ¾ of main base, tack and weld with cross webs. After that bottom plates genend and free end are set up. Tacked and weld on its proper place. Then setand tack and weld the end plates gen end & free end with lo suction pipe. At post L.O. drain plug is set up and dip strike on it proper place. Engine mountfree end and generator end CH/RH, T, welding is to be completed. After fabrication, the main base is sent to H.T.S. for stress reliving at 700 ctemperature and cooled in furnace. Then shot and de burn. Then sent to machine section for complete machining. TURBO SUPPORT FABRICATION :It is the support for turbo which is mounted on cylinder block on free end side. Following components are required for it. 1- Flange bottom 2 2- Back plate 1 3- Side plate l.s 1 4- Side plate R.H 1 5- Flange oil catcher 1 6- Top plate air chamber 1 7- Front wall air chamber 1 8- Bottom Plate 1


Engineering 9- Centre Plate 1 10- Back wall pt. 1 11- Side plate R.S 1 12- Partition plate 1 13- Patch plate 2 14- Gasket 4 15- Pipe segment 1 16-Cover 1 17-Ribs 1 18-Flange 1 19-Side pipes 2 20-Side plate air chamber 1

PROCEDURE OF FABRECATION 1. Dressing and setting of flange bottom and back plate on support. Welding of the flange from the centre of fixture. 2. Setting and tacking of back plate, buck wall and portion plate. 3. Tacking of right side plate on back plate. 4. Welding of 2” I.P.S extra heavy coupling on left side and its setting and tacking on back plate. 5. Grinding ,dressing , setting & tacking of centre on side plate R.S.&L.S 6. Setting & tacking of flange oil catcher. 7. Marking and gas cutting of 4 ¼ “dia hole in bottom plate and welding of ring on the hole of the plate. 8. Setting and tacking of above bottom P.t. on top plate on fixture. 9. Setting and tacking of side R.S 10.Dressing of back wall and its setting and tacking. 11.Setting and tacking of front and bottom plate & front wall. 12.Setting and tacking of pipe segment cover. 13.Inspection hole cutting in front wall. 14.Setting and welding of flange and side piece


Engineering

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