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ISO – 9001:14001 Certified
TRAINING REPORT D. L. W. (Diesel Locomotive Works)
SUBMITTED BY
VIVEKANAND PANDEY B.TECH 3rd YEAR MECHANICAL ENGINEERING
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TABLE OF CONTENTS: 1.
Acknowledgment
2.
Preface
3.
Introduction of D.L.W.
4.
Brief History
5.
Product
• •
6. • • •
6. • • • •
EMD WDP4 Manufacturing Process Engine Division Vehicle Division Block Division Workshops Heavy Weld Shop Light Machine Shop Engine Testing T.M.S.
7.
Organizational Strength
8.
Conclusion
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I would sincerely like to thank the employees & the officers of DLW, Varanasi for their help & support during the vocational training. Despite their busy schedules, they took time out for us & explained to us the various aspects of the working of the plant, from the production shops. I expressed my thanks to the lecturer Mr. D.P. Singh & HOD of department, Dr. B.K. Singh for extending his support. I would also thank my institution & my faculty members without whom this report would have been a distant reality. I also extend my heartfelt thanks to my family & well wishers.
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PREFACE The objectives of the practical training are to learn something about industries practically & to be familiar with the working style of technical person to adjust simply according to the industrial environment. It rightly said practically life is far away from theoretical one. We learn in class room can give the practical exposure or real life experience no doubt they help in improving the personality of the student, but the practical exposure in the field will help the student in long run of life & will be able to implement the theoretical knowledge. 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 Third year mechanical & this report is written on the basis of practical knowledge acquired by me during the period of practical training taken at Diesel Locomotive Work, Varanasi
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INTRODUCTION Diesel Locomotive Works is production unit under the ministry of railway. This was setup in collaboration with American locomotive company (ALCO) USA in 1961 & the first locomotive was rolled out in 1964. This unit products diesel electronic locomotive & DG sets for Indian railways & other customers in India Abroad. Subsequently a contract for transfer of technology of 4000HP Microprocessor Controlled AC/AC Freight (GT 46 MAC) / passenger (GT 46 PAC) locomotive & family of 710 engines has been signed with electromotive division of GM of USA for mfg in DLW is the only mfg of Diesel Electric locomotive with both ALCO & GM technologies in the world.
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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 & spare parts. August
1961
January
1964
January
1976
December
1977
October
1995
March
2002
November March
2002 2003
September
2003
November
2006
March
2007
April
2007
March
2009
November
2009
DLW set as a green field project in technical collaboration with ALCO, USA for manufacture of Diesel Electro Locomotive. First Locomotive rolled out & dedicated to the Nation. Entered Export market, first locomotive exported to Tanzania. First Diesel Generating Set commissioned The Transfer of technology agreement was signed. The first indigenous EMD WDG4 freight locos manufacturing. 3600 HP Engine manufactured The first indigenous passenger version of EMD loco WDG4 manufactured Development of 16 cylinder 330 HP power upgraded DLW engine, WDM3D locomotive DLW manufactured first DG4 locomotive equipped with IGBT based convertor First WDP4 locomotive equipped with IGBT based convertor. DLW has successfully switched over to use of microprocessor based control system on all its l ocomotives. ocomotives. 257 locomotives manufactured in 20082009, highest ever locomotive production. 5690 locomotives up to 30th Nov 2009(including 2009(including 348 EMD locos).
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Types of LOCOMOTIVES PRODUCTION at DLW The first letter (gauge) 1. W- Indian broad gauge( The “W” “W” stands for wide Gauge-5ft) Gauge-5ft) 2. Y- meter gauge( The “Y” stands for Yard guage-3ft) guage-3ft) 3. Z- narrow gauge(2ft 6 inch) 4. N- narrow gauge(2ft) The second latter (motive power) 1. D- Diesel 2. C- DC electric (can run under DC traction traction only) only) 3. A- AC electric electric (can (can run under AC AC traction traction only) only) 4. CA-Both DC & AC (can run under both AC & DC tractions) t ractions) 5. B- Battery electric locomotive (rare) The third letter (job type) 1. G- goods 2. P- passenger 3. M-mixed; both goods & passenger 4. S-Used for shunting (also known as switching s witching engines or switchers in United States & some other countries) 5. U-Electric multiple units (used as commuters in city suburbs) 6. R-Railcars R-Railcars
Ex: - “WDM3A”: “WDM3A”: “W”- broad gauge “D”- diesel motive
“M”- suitable for mixed service “3A”- The locomotive’s power is 3100HP Or, “WAP5”: “W”- broad gauge “A”- AC electric traction motive power “P”- suitable for passenger “5”- denote that this locomotive is chronologically the 5th electric locomotive model Used by the railway for passenger service.
1 •
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DIESEL TRACTION ASSEMBLY AT DLW •
EMD
WDG4- 4000 HP GOODS LOCOMOTIVE
(WDG4 LOCOMOTIVE)
(TRACTION EFFORT & POWER CHART)
Diesel Engine •
16 cylinder 710G3B, 2 turbocharger. After cooled.
Transmission stroke,
•
Fuel Efficient Engine
•
Injection System? direct Unit Injector
•
Governor? Woodward
•
Compression Ratio 16:1
•
Lube Oil Sump Capacity 950Lts
Truck
•
•
•
•
Electrical Ac-Ac 6 Traction motor (3in parallel per bogie) Suspension? Axle hung/taper roller bearing. Gear Ratio 90:17
Brakes
•
High adhesion HTSC (High Tensile Steel Cast)truck of bogie
•
Electronic Air Brake System(KNORRNYAB-Computer Controlled Braking)
•
Adhesion 0.42
•
Air, hand, dynamic brake
•
Pure air brake
General Characteristic •
Installed Power
•
4000HP
•
Axle Load
•
21 T
•
Gauge
•
1676mm
•
Wheel arrangement
•
Co-Co
•
Wheel diameter
•
1092mm
•
Height
•
4201mm
•
Width
•
3127mm
•
Overall Length(Over Buffer Beam)
•
19964mm
•
Weight
•
126 T
•
Max tractive effort
•
54 T
•
Maximum speed
•
100Kmph
•
Fuel tank capacity
•
6000Lts
•
Locomotive control
•
EM 2000 Control
with
SBIAS-16
Traction
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WDP4- 4000HP PASSENGER LOCOMOTIVE
Diesel Engine •
•
•
Transmission
16 Cylinder 710 G3B, 2 stroke, turbocharged � after cooled
•
Fuel Efficient Engine Injection System � Direct Unit Injector
•
Governor � Woodward
•
Compression Ratio- 16:1
•
•
•
•
Electrical AC-AC 4 Traction motor ( 3 in parallel per bogie) Suspension � Axle hung / taper roller bearing Gear Ratio � 77:17
Lube Oil Sump Capacity � 1073Lts Truck
•
•
Brakes
High adhesion HTSC ( High Tensile Steel Cast) truck or bogie
•
Adhesion � 0.42 •
•
Electronic Air Brake System ( KNORR-NYAB-Computer Controlled Braking) Air , hand , dynamic brake with fully blended with automatic brakes Pure air brake
General Characteristic •
Installed Power
•
4000 HP
•
Axle Load
•
19.5 T
•
Gauge
•
1676 mm
•
Wheel arrangement
•
A-A-I I-A-A
•
Wheel diameter
•
1092 mm
•
Height
•
4201mm
•
Width
•
3127 mm
•
19964 mm
•
117 T
•
27 T
•
160 Kmph
•
4000 lts
•
Overall Length (Over Buffer Beam)
•
Weight
•
Max tractive effort
•
Maximum speed
•
Fuel tank capacity
•
Locomotive Control
•
EM 2000 with SIBAS-16 Traction Control
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ALCO:-
•
1350 HP CAPE CAPE GAUGE GAUGE LOCOMOTIVE LOCOMOTIVE VDM4
TECHNICAL INFORMATION
1350 HP Locomotive having fabricated cape gauge Co-Co bogie. hese locomotives have been supplied to Angola and Sudan. Wheel Arrangement
Co – Co
Track Gauge
1067 mm Cape gauge
Weight
72 t
Overall Length
15600 mm
Wheel Diameter
921 mm
Gear Ratio
18: 93
Maximum Speed
90 Kmph
Diesel Engine
Type: ALCO 251 D 6Cyl. In l ine.
HP
1350
Transmission
Electrical AC/DC
Brake
28LAV-1 system
Loco
Air, dynamic, parking
Train
Air & Vacuum
Fuel Tank Capacity
3000Litres
2300 HP CAPE GAUGE LOCOMOTIVE
TECHNICAL INFORMATION 2300HP Main Line Locomotive, having fabricated cape gauge Co-Co bogies. These are provided with two drivers cabs, one at each end. These locomotives have been supplied to Angola and Sudan. Wheel Arrangement
Co-Co
Track Gauge
1067 mm Cape Gauge
Weight
102 t
Overall Length
17620 mm
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Wheel Diameter
921 mm
Gear Ratio
18 : 93
Maximum Speed
100Kmph
Diesel Engine
Type: ALCO 251-B 12Cyl. V- Engine
HP
2300
Transmission
Electrical AC/DC
Brake
IRAB-1
Loco
Air, Dynamic, parking
Train
Air
Fuel Tank Capacity
3000Litres
2300 HP METER GAUGE LOCOMOTIVE
TECHNICAL INFORMATION
2300HP Main Line Locomotive, having fabricated meter gauge Co-Co bogies. These are provided with two drivers cabs, one at each end. These locos have been supplied to Malaysia, Senegal and Mali. Wheel Arrangement
Co-Co
Track Gauge
1000 mm Meter Gauge
Weight
102 t
Overall Length
17620 mm
Wheel Diameter
921 mm
Gear Ratio
18 : 93
Maximum Speed
100Kmph
Diesel Engine
Type: ALCO 251-B 12Cyl. V- Engine
HP
2300
Transmission
Electrical AC/DC
Brake
IRAB-1
Loco
Air, Dynamic, parking
Train
Air
Fuel Tank Capacity
3000Litres
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3000 HP CAPE GAUGE LOCOMOTIVE
TECHNICAL INFORMATION (Provisional Specifications)
3000HP Micro Processor Controlled, Main Line, Cape Gauge Locomotive with improved Cab, under development for Mozambique Railway Wheel Arrangement
Co-Co
Track Gauge
1067 mm Cape Gauge
Weight
114 t
Overall Length
18632 mm
Wheel Diameter
1000 mm
Gear Ratio
19 : 92
Maximum Speed
100Kmph
Diesel Engine
Type: ALCO 251-C 16Cyl. V- Engine
HP
3000
Transmission
Electrical AC/DC
Brake
IRAB-1
Loco
Air, Dynamic
Train
Air
Fuel Tank Capacity
6000Litres
1350 HP METER GAUGE LOCOMOTIVE YDM4
TECHNICAL INFORMATION
1350HP Locomotive having cast / fabricated meter Gauge Co-Co bogie . Such locomotives have been supplied to Vietnam and Myanmar . Wheel Arrangement
Co - Co
Track Gauge
1000 mm
Weight
72 t
Overall Length
15600 mm
Wheel Diameter
965 mm
Gear Ratio
18: 93
Maximum Speed
96Kmph
Diesel Engine
ALCO 251 D 6Cyl. In line.
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HP
1350
Transmission
Electrical AC/DC
Brake
IRAB � 1 system / 28LAV-1
Loco
Air, dynamic, parking
Train
Air / Dual (Air and Vacuum)
Fuel Tank Capacity
3000Litres
BROAD GAUGE MAIN LINE FREIGHT LOCOMOTIVE WDG 3A
TECHNICAL INFORMATION
Diesel Electric main line, heavy duty goods service locomotive, with 16 cylinder ALCO engine and AC/DC traction with micro processor controls Wheel Arrangement
Co-Co
Track Gauge
1676 mm
Weight
123 t
Length over Buffers
19132 mm
Wheel Diameter
1092 mm
Gear Ratio
18 : 74
Min radius of Curvature
117 m
Maximum Speed
105Kmph
Diesel Engine
Type : 251 B,16Cyl.- V
HP
3100
Brake
IRAB-1
Loco
Air, Dynamic
Train
Air
Fuel Tank Capacity
6000litres
BROAD GAUGE MAIN LINE MIXED SERVICE LOCOMOTIVE WDM 3D
TECHNICAL INFORMATION
Diesel Electric Locomotive with micro processor control suitable for main line mixed Service train operation.
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Wheel Arrangement
Co-Co
Track Gauge
1676 mm
Weight
117 t
Max. Axle Load
19.5 t
Length over Buffer
18650 mm
Wheel Diameter
1092 mm
Gear Ratio
18 : 65
Maximum Speed
120Kmph
Diesel Engine
Type: 251 B-16Cyl. �V� type (uprated)
HP
3300 HP (standard UIC condition)
Transmission
Electric AC / DC
Brake
IRAB-1 system
Loco
Air, Dynamic, Hand
Train
Air
Fuel Tank Capacity
5000litres
BROAD GAUGE SHUNTING LOCOMOTIVE WDS 6AD
TECHNICAL INFORMATION
A heavy duty shunting shunting Diesel Diesel Electric Locomotive Locomotive for for main line and branch line line train operation. This locomotive is very popular with Steel Plants and Port Trusts. Wheel Arrangement
Co-Co
Track Gauge
1676 mm
Weight
113 t
Length over Buffer
17370 mm
Wheel Diameter
1092 mm
Gear Ratio
74 : 18
Maximum Speed
50Kmph
Diesel Engine
Type: 251 D-6Cyl. in-line
HP
1350 / 1120 HP (std.)
Transmission
Electric AC / DC
Brake
IRAB-1
Loco
Air
Train
Air
Fuel Tank Capacity
5000litres
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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, laser hardened cylinder liners, connecting rods and various gears. Our well-equipped Machine Shops have dedicated lines for operations like turning, milling, gear hobbing, 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 process like heat treatment and induction hardening are also carried out in-house. A new eco friendly laser hardening machine has been setup which is designed to laser harden the inner bore of engine cylinder liner and this feature advantages such as low running cost, state of the art controls to provide reliable and versatile laser power for ultimate quality requirements.
Engine Assembly & Testing Pre-inspected engine block, crankshaft, cylinder liners, pistons, connecting rods, cylinder heads, exhaust manifold, turbo supercharger and all related piping are used in assembly of engine. Electrical machines like traction alternator, auxiliary generator and exiter are thereafter coupled on the engine.
The complete power packs with electrics are tested on computerized Engine. Test Bed to verify prescribed horsepower output. Vital parameters of engine health are checked to assure the quality of product. Only after the engine parameters are found perfect the power pack are cleared for application on locomotives.
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•
LOCO DIVISION Component Fabrication
Precision cutting and forming of sheet metal is utilized 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 equipment is assembled assembled in the fabricated control compartments and driver's control stands are 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 are tested radio-graphically. Welder training and their technical competence are periodically reviewed. High Horse Power (HHP) under frame is fabricated using heavy fixtures, petitioners 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 utilized for machining 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.
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The complete truck (bogie), including bogie frames, wheels and axles, brake rigging and traction motors are assembled which is r eady for application to locomotive.
LOCOMOTIVE ASSEMBLY Tested engines are received from Engine Division. Similarly under frames are received from Loco frame shop and assembled trucks from Truck machine shop. Superstructure compartments and contractor compartment are received from respective manufacturing and assembly shops of Vehicle Division. Important alignments like crank shaft deflection; compressor alignment and Eddy Current clutch/radiator fan alignment are done during assembly stage.
Electrical control equipments are fitted and control cable harnessing is undertaken. The complete locomotive is thus assembled before being sent onwards for final testing and spray painting. All locomotive are rigorous tested as per laid down test procedures before the locomotive is taken up for final painting and dispatch for service. •
BLOCK DIVISION
Flame Cutting of Components Steel plates of sizes up to 80 mm thickness 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/ Crankcase 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.
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Fabrication of engine block is completed by submerged arc welding using semiautomatic 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 re-qualifi ed for the assigned. After complete welding weldment 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 10µ enables adhering to the tolerance required on engine block .
Angular Boring Machine Angular boring "V" boring is done of special purpose machine which is a special purpose machine, which has two high precision angular boring bars on which different boring inserts are mounted. The cutting inserts on boring bars to achieve evenly distributed cutting load during boring operation. This contributes to accuracy while machining.
Boring bars are mounted on high precision bearings which provide control on size during angular boring. The machine is capable of boring and drilling to different sizes.
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WORKSHOP
HEAVY WELDING SHOP(HWS) LIGHT MAHINE SHOP(LMS) ENGINE TESTING(ET) TRUCK MACHINE SHOP(TMS)
This shop deals with the matching of various small component required for the power pack unit such as, cam shaft, connecting rod, liners, gears levers, F.P. Support, Piston pin, nuts & bolts bushes, various shafts etc.
HEAVY WELDING SHOP(HWS)
This shop mainly deals with fabrication of the engine block and base (B.G & M.G) Turbo support after cooler housing items. The engine block is structural member of the diesel engine. It is composite weldment with heavy plates thickness varying from 16 mm to 75 mm & 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” * 7” thickness conforming to be 1895.
1. DIFFERENT WELDING PROCESS USED IN HEAVYWELDING SHOP (H.W.S.)Electric arc welding. Gas welding Forging welding. • • •
Joining of two components by gas electric arc or forge of same or different material homogeneous and dense joint is called welding. 2. Blocks in DLW-HWSa. ALCO (American Locomotive) block Power 6 cylinder 2300hp 12 cylinder 2600hp 16 cylinder 3300hp
V Type Engine 45¶ alignment 45¶alignment
b. GM (general Motor) block or EMD (Electromot (El ectromotive ive Division) block Power 16 cylinder 4000hp 20 cylinder 5000hp
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3. ALCO components A. Saddle No. of use
width
Intermediate Intermediat e Saddle
07
4.5”
Center Saddle
01
6.75”
T Saddle
01
4.625”
B Foundation Plate (L & R)
Two ends free and generator end L and R Foundation plates are decided by Generator. c. Spines D. Outside walls L R E. Middle deck L R F. Inside wall L R G. Top deck L R
Width 20mm 20mm Width 40mm 40mm Width 16mm 16mm
In spine welding root run takes place from 1, 3, 5, 7, 9 and then 2, 4, 6, 8.In root run, 4.5 to 5mm electrode is used for welding. After root welding 6.5mm electrode is used. X-ray quality joints are produced in ALCO. 4. Welding types in HWS a. Manual metal arc welding (MMAW) b. Gas metal arc welding (GMAV) c. Submerged welding ± shielding is provided by flux. On the basis of use - Internal submerge welding - External submerge welding CO2 and agro shield (Argon 82% and CO2 18%). CO2 creates shield and wt off the contact of flux from environment and prevent oxidation of metal,
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5. Tandem welding:Used for heavy metal deposition. Use A.C. and D.C. current both for welding. DC arc lead AC arc transition welding process. Heat input is very low. Good penetration is obtained. It is one time welding process while in internal and external submerged welding the process can be repeated several times. 6. Stress relieving: After After complete block fabrication heat treatment is done. We put block into diesel furnace for 28hours.Temprature arises into diesel furnace. At rate 0f 50’per hour and reach upto 450’C and then rises at the rate of 30’c per hour upto 640’c. At 640’c block is kept in furnace for 10 hours and its temp. Reaches at range of 250-280’c.
Coating: - Electrode is coated by iron dust and other filler material. Coating is done for shielding of welding process. Type of coating: a. Low coating ± Deposition efficiency 110%. b. Medium coating - Deposition efficiency 110-129% c. Heavy coating - Deposition efficiency 129-140% d. Super heavy Coating - Deposition efficiency 140-220%. Deposition Efficiency:It is defined as the ratio of amount of material included is weld to the amount of material supplied.
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Light
Machine Shop (LMS)
About 240 spare parts parts required by DMW and Zonal Zonal Railways for locomotive locomotive maintenance including Camshafts, Cam & Split Gears, Bull Gears, Valve gear components, Equalizer beams, Axles, Armature shafts, Gas inlet casings, etc. are manufactured in the Light Machine Shop. DMW was the first Production Unit of the Indian Railways to adopt NC-CNC machines on a large scale.
The light machine shop divided into the following section:I. II. III. IV. V. VI. VII. VIII. IX. X. XI.
Econometric section Grinding section Gear section Cam shaft section A.T.I. section Belching section Connecting rod section Lathe section Liners section Drilling section Milling section
Connecting rod section: In this section the connecting rod is made. All the machining operations of the connecting rod. Completed here with the help of various types of machine. The connecting rod has two parts; one is cap and other is rod. The material of the connecting rod is steep forging. In B.G. 16 per loco and in M.G. 6 per loco.
Main dimensions 1. Crank bore (big bore) =6-411ǁ”to 6.421” 2. Piston pin bore (small bore) =3.998”to 3.999” 3. Distance between Two = 20.995” to 21.000” bare centre 4. Rod Thickness = 3.020” to 3.022” 5. Weight = 32 Kg 950 gram to 3 2 Kg gram. 6. Pressure Torque = 150 P.S.I
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1. Econometric section:This section manufacturing various sizes etc. Machine provided: - Econometric machine, do-all machine, belt grinding machine (for control shaft feed) 02. Gear- Section: -
This section deals to making various gears impeller such as: camshaft gear, crank shaft gear, extension shaft gear, impeller gear (follower& drive) and broaching Machine Provided:(a) Gear hobbling machine (b) Gear shaving machine (c) V.T.L. machine (d) Radial drilling machine (e) Broaching machine & (F) Centre mill M/C 03. Grinding Section: In this section the various small components are grinding as per re quired finishing after machining operation and each components having grinding allowance (G.A.) main piston pin, impeller and fuller and follower gear, pin valve guide, various studs. Cam roller, seat (V/C Q ‘X‘head) spider various bushes etc. Machine provided (a) Cylindrical grinding machine (b) Internal grinding machine (c) Centre less grinding machine (d) Thread rolling machine (e) Universal grinding machine (f) External grinding machine 04. Camshaft section
This section making cam shaft (both B.G. & M.G.) with completed m achining operation by various special type of machine. In B.G. 08 nos per loco a nd in M.G. 03 per loco. Machine Provided
1. Centre mill machine 2. Auto lathe machine 3. Gun drill machine 4. External grinding machine 5. Lathe machine 6. Cam grinding machine 7. Radial drilling machine 8. Cam angle checking machine 9. Magna flux machine
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Cam 16 B731
Cam 16B
Cam shaft length size (B.G.) shaft no. Do all size 73 39 29/32” 74 37 1/8” 75 39 3/8” 76 47 11/32” 77 43 3/32” 78 37 1/8” 79 47” 80 38 17/32”
Milling size? 39.656” 36.875” 39.125” 47.093” 42.843” 36.875” 46.750” 36.281”
Cam shaft length size (M.G.) shaft no. Do all size 95 33 3/8” 96 32 7/8” 97 41 13/32”
Milling Size? 33.125” 32.625” 41.156”
Air cam Fuel cam
7 7
Cam angle angle angle
Ex. Cam
7
angle
238.936
238-56
Air cam
8
angle
45.769
45-46
Fuel cam
8
angle
57
Ex. Cam
8
angle
328.936
315.769” 327
315-46
328-56
05. Automatic Turret Lathe (A.T.L) Section:-
This section manufacturing various types of s mall components for Power pack engine such as: Lock spring seat (V/L & X-Hd) spewing seat. Ball end, cup end ad Screw (X-HD & V/L) cop screws L.A.S. retainer, spring lever, F.P. inlet, Porg Bkt. piston pin liner sleeve, body outer ring spicier spicier etc. machine provided. provided. 1. M.T.L. (Bar type, chuck type) 2. U.T.L
The A.T.L. section is the vital section of this shop. Maximum small components are manufacturing in the section 06. Benching Section:
In this section the benching operation of the entire component which are manufacturing in the shop are done here. In the benching section. There hawing hand cutter machine and belt grinding machine, with the half of these machine bar removing from all the components.
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07. Cyl. Liner Section: In this section .cycle liner machine operation have done here by the various type of m/cs. the material of the cyl. Liner is spe. Cast iron and the set the per loco is in B.G. 16 and in M.G. 6 cylinder Main Dimension:1. Length 21 15/16 + 1/64 2. Inside dia rough honing -9.010” 3. Inside dia finish honing – 9.015” 4. outside dia – 10.00” 5. Dia of groove– 10.749 to 10.750” Machine provided:1. Shot blast machine. 2. Vertical boring machine 3. Auto lathe machine. 4. Honing machine. 5. Cylindrical grinding machine
08. Lathe section:
This section deals various types tropical small components are manufacturing. Centre lath machines or provided in this section. The components are: brass sleeve, wear plate, valve guide, long stud, shaft etc.In drum type turret lathe M/C manufacturing pin cam roller, cup end, bush washer etc. 09. DRILLING section:In this section dials with various Types of drilling, reaming, counter bore spot tracing and counter sinking operation done of various small components. The components are, F.P. support, P.R. Lighter, X head, Valve Lever, Spring Lever, Brg, Bracket, Pin, Ecc Lever, Upper housing etc. MACHINE PROVIDED:-
1. Radial drilling Machine, 2. Gang drilling machine of multi spindle drilling machine 3. Drilling Machine 4. Electronic drilling machine. 10. MILLING MACHINE:This section manufacturing various types of milling operation of the components in types of milling machine. MACHINE PROVIDED:-
1. Vertical milling machine 2. Horizontal milling machine 3. Universal milling machine.
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CAM -SHAFT OBJECTIVE: -
The Cam shaft is made replaceable section of heat treated precision machined alloy steel with chromium. The Cams are formed internal with shaft and bearing and Cam Surfaces andhardenedby high frequency induction. Shaft is driven from the crank shaft through a forged steel heat treatedspan type gear train of adjusted adequate diameter and face width. The push rod lifter having contact with its cams through their rollers over the valves air inlet and exhaust gases. The middle cross head lifted operates the injection to inject the fuel. In the generator end of cam shaft a gear is coupled with which gives the motion to turbo generator which generate the electricity for the governor of the engine. In the other end of the cam shaft a carrier weight is linked after the cam shaft vibration dumper which is housed in O.S. Trip assly and operate stripping of system. Through its plunger that is opened by the centrifugal force of cam shaft rotation. PROCEDURE: Four shafts having no 77, 78 79 +80for right side ware leaned thoroughly. Passed the dowel pins in holes of 0.499” Kept these shafts on leveled co- boars with the pilots. The sequence of number male and female flanges must be like 77, 78, 79&80respectivesly .applied 18 no studs of y2 N.F. and fastened items with Elastic stop nuts 36 no. applied y2” plug on generator end. Similarly other four shafts having SL. no. 73, 74, 75, &76 for left side were assly. Material specification: - M.S., CR steel D.81602HR application of camshafts for the different engines is as follows:M.G. 95, 96, +97 B.G. 73 74 75 &76, 77, 78, 79, & 80 L.S. R.S. WDML: - 107, 108, &109/ L.S., 104, 105, &106/ R.S. VIBRATION DAMPER ASSEMBLY.CRANK SHAFT (TYPE 251 B) OBJECTIVE:The Vibration damper is fitted with crank shaft to prevent the vibration of crank shaft when the engine starts the Crank shaft gets a sudden shock the VibrationTrademark diminishes these shocks. In the same way when the engineStops unexpectedly the crank shaft gets a heavy shock. So the get heavy shock. So we gets reduced of these shocks we use the vibration damper asa safety device and to increase the life of crank shaft. Material:-Outer ring steel 54190Intermediate ring steel 54190Spider cast iron 8054 PROCEDURE: -Debarred the holes of outer ring and screw hole of 1 by2” Applied lye bolt in the threaded holds cleaned. Placed the outer ring plate on a round wooden piece of 6ǁ height from centre Bore side of it to downward. Place the intermediate ring on the outer plate dropped a little oil on the top of the intermediate ring.
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Engine Testing:Engine test operation sequence: 1. Bare inspection under screen and fitting over screen. 2. Water circulation. 3. Lube oil filling f illing and check deflection crankshaft. 4. Lube oil circulator. 5. Pre runs no load ± 3runs 5, 10, 30 minutes (400rpm). 6. Intermediate runs 12 runs of 30 minutes duration each from 400rpm to1000rpm.Load 68 to 2330bhp. 7. Check over speed trio of re-check three times. 8. Check brake in nozzles and set tapped clearance. 9. Inspection before first hour performance. 10. First hour performance on full load. 11. Base inspection. 12. Second hour performance on full f ull load. 13. Attend defects of first hour performance. 14. Final base inspection. 15. Check engine deficiencies. 16. Engine clearance. Lubricating oil testing Lubrication is done for better performance of the e ngine parts. testing is done by checking the circulation of lubricant oil. for rotating parts checking is done by seeing the returning path of the oi l i.e. checking not only the forward path but also the returning path. RR40 is used as lubricating oil
Water testing Water acts as a coolant for moving part of the engine because constant movement or rotation causes various parts to heat up and water working as coolant cooled down the concerned part. Load testing For load testing electrical load is provided to the engine. If there is any abnormal sound then the engine is again tested for lubrication so that any flaw which is there can be removed. re moved.
Engine assembly partsCrank case Oil pan Power assembly(16 no) Crank shaft (1 no.) Cam shaft (RS & LS) • • • • •
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• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
Control shaft (RS & LS) Head frame (RS & LS) Turbo supercharger Alternator Injector Oil separator After cooler (R & L) After cooler duct (R & L) Woodward Governor Governor drive O.S.T. device Detector assembly Thermostatic valve Water pump (R & L) Main lube oil pump Scavenging lube oil pump Lube oil strainer Soak back pump Cranking motor (starting motor) Turbo lube oil filter Soak back filter Ring gear Flexible coupling Ring gear coupling Auxiliary drive O.S.T. shaft (R & L) Rocker arm (16 set) Fuel oil injector (16 no) Cylinder head assembly (16 no) Connecting rod (6 no) Governor booster pump Fuel oil manifold Fuel oil junction box
1. Valves For a two-stroke engine, there may simply be an exhaust outlet and fuel inlet instead of a valve system. 2. Exhaust systems The exhaust system frequently contains devices to control pollution, pollu tion, both chemical and noise pollution.
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3. Cooling systems Combustion generates a great deal of heat, and some of these transfers to the walls of the engine. Cooling systems usually employ air or liquid (usually water) cooling. 4. Piston: It is located in a cylinder and is i s made gas-tight by piston rings. Its purpose is to transfer force from expanding gas in the cylinder to the crankshaft via a piston rod and/or connecting rod. In two-stroke engines the piston also acts as a valve by covering and uncovering ports in the cylinder c ylinder wall. 5. Crank shaft: Most reciprocating internal combustion engines end upturning a shaft. This means that the linear motion of a piston must be converted into rotation. This is typically achieved by a crankshaft. 6. Starter systems: All internal combustion engines require some form of system to get them into operation. Most piston engines use a starter motor powered by the same battery as runs the rest of the electric systems. 7. Lubrication Systems: Internal combustions engines require lubrication in operation that moving parts slide smoothly over each other. Insufficient lubrication subjects the parts of the engine to metal-to-metal contact, friction, heat build-up etc. 8. Alternator Alternators generate electricity by the same principle as DC generators, namely, when the magnetic field around a conductor changes, a current is induced in the conductor according to faraday’s law of electromagnetic induction. 9. Governor a device used to measure and regulate the speed of an engine. The microcontroller based governor consists of a control unit mounted in the drive cab and an actuator unit mounted on the engine. The governor controls the engine speed based on throttle handle position. Engine RPM is measured by an engine speed sensor mounted on the engine. Air pressure is measured through a pressure sensor mounted in air manifold, and movement of fuel rack is limited as a function of this pressure so as to prevent incomplete combustion, combustion, black smoke, excessive engine temperature, temperature, fuel wastage etc. 10. Control unit features • 16 bit microcontroller based design • No need of regular maintenance. • Effective control for complete combustion of fuel improves fuel efficiency and reduces pollution. • Continuous display of engine status parameters. • Online fault diagnostics and fault message display.
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11. THROTTLE It is the mechanism by which the flow of a fluid is managed by constriction or obstruction. r estriction of inlet An engine's power can be increased or decreased by the restriction gases. A throttle position sensor (TPS) is a sensor used to monitor the position of the throttle in an internal combustion co mbustion engine. The sensor signal is used by the engine control unit (ECU) as an input to its control system. The ignition timing and fuel injection timing are altered depending upon the position of the throttle, and also depending on the rate of change of that position. Engine control units control engines by determining deter mining the amount of fuel, ignition timing and other parameters, by monitoring an engine through sensors, and reading values from fro m multidimensional maps. 12. Traction motor • Electric motor providing the primary rotation a 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.
FIRING ORDER IN CYLINDER Front End
Left Bank
firing order
Right Bank
Lube Oil & Water Pumps Governor • • • • • • • •
9 10 11 12 13 14 15 16
• • • • • • • •
Engine Air Inlet & Flywheel
Rear End
1 2 3 4 5 6 7 8
1 9 3 11 4 12 2 10
8 16 6 14 5 13 7 15
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Truck Machine Shop (TMS) 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 bogie •Bo-Bo bogie bogie 1. Co-Co bogie: Co-Co bogie has three axles and six wheels.
2. Bo-Bo bogie: Bo-Bo bogie has two axles and four wheels.
Manufacturing of bogie: There are two of manufactured bogies
1. Fabricated bogie: In fabricated bogie, bogie made by the cutting and welding. In DLW fabricated bogie uses mostly. 2. Casting bogie: In the casting bogie, bogie is manufactured by casting
Important parts of bogie: 1. Bogie frame: A bogie is a wheeled wagon or trolley. In mechanics terms, a bogie is a chassis or framework carrying wheels, attached to a vehicle. Bogie on which super structure and under frame is mounted. It is two type Co-Co and Bo-Bo bogie. Co-Co has three axles and six wheel and Bo-Bo has two axles and four wheel. whee l.
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2. Axle: EMD engine axle has three holes but in ALCO engine axle has eight Holes. 3. Wheel 4. Bull gear 5. Suspension tube 6. Axle boxes
7. 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. 8. Brake riggings items 9. Air pipe
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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 212 4 Crore. State of the art Design and Manufacturing facility to manufacture200 locomotives per annum with wide range of related productsviz. DG Sets, Loco components and sub-assemblies. Supply of spares required to maintain Diesel Locomotives and DG sets. nbeatable 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 rice- 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 olicy Diesel Locomotive Works is a roduction nit n it 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 - at- work -place performance. pe rformance. reventing pollution by all means including minimizing resource consumption and waste generation using cleaner technologies, material substitution and process changes. reventing all injuries and loss of property including inc luding environmental performance through continuous safety inspections.
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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. reventing 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
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 eve r 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:
ST is mainly concerned with the treatment of domestic and industrial sewage. The treated water is used for irrigation purpose up to nearby ne arby Lohta farm and kitchen gardening at DLW premises. The digested sludge is sent to sludge drying beds, later to be used u sed as manure. Methane gas mainly produced from the digester is collected in the gas holder and supplied to the canteen.
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Industrial Effluent Treatment Plant:
IET 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:
CT deals with the treatment of effluents from CR shop (Chrome lating 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, c akes, is stored in a covered tank made of concrete. Water after treatment is used for irrigation in nearby villages.
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 productivi ty.. OHS Objectives: • Reduction in HOD cases -10% every year • Improvement in use of PPEs (100%) • Recharging of Ground water
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INNOVATIONS IN GLOBAL LOCOMOTIVES Why diesel-electric locos? Diesel is a non renewable source of energy and can’t be replenished once finished. So why not go for electric locomotives, which pick up electrical power from an overhead wire or a third rail laid beside the track? When I asked this question from my project guide, he simply answered that the cost of electric transmission lines is huge and also The first cost of an electric locomotive is far greater than a diesel locomotive. Hence even at those places where transmission lines have been laid, diesel-electric locos are still used! Recent trends Recent innovations in technology have been driven by a desire to find safer, faster, and more reliable means of getting from place to place. For passenger transportation, speed and convenience are primary goals. For freight transportation, speed, reliability, and efficiency, or carrying more cargo for less money and arriving on time, have been the motivating factors. The diesel-electric locomotives cannot go on indefinitely and there is need to look for smarter methods in locomotive transport sector. Most modern transportation systems rely on petroleum for energy, but this source of energy is finite and creates serious environmental effects when used in the internal-combustion engine. Research into alternative fuel sources, such as electrical storage, natural gas, methanol, ethanol, fuel cells, and solar energy, will continue in order to ensure a reliable supply of energy for the transportation systems of the world. Several new forms of propulsion are also being investigated. Several technologies that are shaping society in a variety of ways will likely characterize the future of locomotive transportation. transportation. Intelligent transportation systems apply the latest advances in computers and electronics to better control vehicle operations. Computerized road maps used with the Global Positioning System (GPS) help drivers to navigate. Research is also being conducted into improving the materials used for constructing the locomotives. Composite material, which is a hybrid consisting of many different component materials, can provide lightweight, extremely strong, and highly durable material for loco construction. With the lighter weight, locos can become more fuel efficient. Explained on the following page is the working of a magnetically levitated locomotive that very surely is the technology of the future! f uture!
VALUE ADDITION
After completing this project, I can now feel that I have learnt a great deal and also had this excellent opportunity to get some useful exposure of industry. I have had a closer look on the various machining operations in my shop. I had a chance to visit different shops and learnt about their working and had a good idea about an EMD- LOCOMOTIVE.
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