1 1. Or Orga gani niza zatio tion n Ove Overv rvie iew w
1.1. Type of organization: Diesel Locomotive Works (DLW) established in 30 April 1956. Diesel Locomotive Works (DLW) got its first ISO certification in 1997, recently DLW has obtained the “integrated Quality and environment management system” certification based on ISO9001 and ISO14001 in December 2002.DLW is proud to be the pioneer in this area amongst the government/public sector units in the country. Diesel Locomotive Works (DLW) is the organization of Indian railways. Diesel Locomotive Works (DLW) is the organization which makes the diesel electric rail engine for the Indian railway. Diesel Locomotives Works (DLW) is making two types of diesel electric rail engine for the Indian railways. These two types of rail engines are ALCO and EMD diesel rail engine. Diesel Locomotive Works (DLW) also makes DG Set for the Indian railways.
1.2. Manufacturing:
Diesel Locomotive Works (DLW) manufactures the diesel electric locomotive engine for Indian railways. Diesel Locomotive Works (DLW) manufactures two types of diesel electric locomotive engine. First one is ALCO type of diesel electric engine. It is 4 stroke engines so it is produces less power. That’s why this type of diesel engine has less production. Second type of diesel engine is EMD engine. It is 2 stroke engines. So it is produces more power so it is also known as High Horse Power (HHP) or General Motor (GM).
1.3.Location:
Diesel Locomotive Works (DLW) is located in the India’s holy city Varanasi (Uttar Pradesh). In the Varanasi Diesel Locomotive Works (DLW) place around 300 hectares. This Diesel Locomotive Works (DLW) helps in the progress of the Indian railways and India.
2 of Work Culture in the Diesel Locomotive Works (DLW): (DLW): 1.4. Specialization of Work
In the Diesel Locomotive Works (DLW) they are following specialization of work culture:
1.4.1. Flame Cutting of Components:
Steel plates of sizes up to 80 mm thickness are ultrasonically tested before being precision cut by numerically numerically controlled controlled flame flame cutting cutting machines, machines, Plasma Plasma Cutting Cutting Machine.
Components are straightened and machined prior to fitting & tacking on fixture designed especially for engine block fabrication to ensure close tolerance on engine block. 1.4.2. 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.
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Down-hand welding is ensured using specially designed positioners. 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 for the assigned.
After complete welding weldment is stress relieved and marking is done for subsequent machining.
1.4.3. 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”enables adhering to the tolerance required on engine block.
4 1.4.4. Angular Boring Machine:
Angular boring "V" boring is done of special purpose machine which is a special purpose machine, machine, which which has two two high precision precision angular angular boring boring bars on which which different different boring inserts are mounted. mounted.
The cutting inserts on boring bars to achieve evenly distributed cutting load during boring operation. operation. This This contributes contributes to accuracy while machining 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.
1.4. 1.4.5. 5. Comp Compon onen entt mac machi hine ne::
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.
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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.
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1.4.6. 1.4.6. Engine Engine Assemb Assembly ly & Test Testing ing::
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 pack 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.
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Only after the engine parameters are found perfect the power pack are cleared for application on locomotives.
1.4.7. 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 are done in another work area.
8 1.4.8. 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, positioners to ensure down hand welding. Fixtures are used to ensure proper fitting of components and quality welding in subsequent stages.
9 1.4. 1.4.9. 9. Bogi Bogiee Manu Manufa fact ctur urin ing: g:
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. The complete truck (bogie), including bogie frames, wheels and axles, brake rigging rigging and and traction traction motors motors are assembled assembled which which is ready ready for application application to locomotive.
1.4.10. 1.4.10. Loco Assembly: Assembly:
Tested engines are receives 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 the locomotive locomotive is taken up up for final final painting painting and dispatch for service. service. 1.5 About the External Guide:
10 In diesel locomotive works (DLW) there are Section Engineer (SE) who guides by the taking lecture in the lecture hall and give the knowledge about the cylinder block machining, EMD engine, Engine testing, Under frame manufacturing process, Bogie, Loco assembly, Loco Testing method, different type of locomotive and there nomenclature etc. Mr. Ravi Gupta sir who is section engineer in the HWS told about the cylinder block machining and there operations. Mr. Sanjay Kumar sir who is section engineer in the Engine shop told about EMD engine and its firing order. Mr. Ajay Verma sir who is section engineer in the Engine Testing Shop (ETS) told about engine testing. Mr. A.K Shrivastav who is section engineer in Loco Frame Shop (LFS) told about the under frame manufacturing process. Mr. Ashok Kumar Kharwar who is junior engineer in Light Machine Shop (LMS) helped during the summer vocational training. Many workers also helped during the vocational training and told many things. 2
Tecchnolog Te ology y Le Lea arnt rnt
In Diesel Locomotive Works (DLW) there are many Workshops for learning and visiting. These workshops are HWS, HMS, EES, ETS, LMS, LAS, SAS, RS, HTS, LFS, PS, TMS, TAS, SMS, LAS, LPS, and LTS etc. These are the workshops in the Diesel Locomotive Works (DLW) where student get knowledge about practical experience. There are some workshops in TTC (Technical Training Center) like Fitting shop, Machine Shop and Welding Shop. In Diesel Locomotive Works (DLW) I have visited 6 Works shop in six week. These works shop are Fitting shop, Machine shop, HWS (Heavy Welding Shop), LAS (Loco Assembly Shop), RS (Rotor Shop) and TMS (Truck Machine Shop).
2.1 Fittin Fitting g Shop Shop
11 First week I have visited fitting shop. This is inside the TTC (Technical Training Center). In the fitting shop workers of diesel locomotive works (DLW) learn about the fitting. In the fitting shop I have visited many things Fitting tools:
The tools use in fitting shop is classified into following groups. Measuring tools:
These tools are use to measure the length, Diameter and height. These measuring tools are Steel Rule, Inside Caliper, Outside Caliper, Vernier Caliper and Micro meter. Holding device:
These device is use to hold the job. In have seen Parallel Jaw Vice is use to hold the job in fitting shop. Cutting tools:
These tools are use for cutting the job. I have seen these cutting tools in DLW fitting shop Hacksaw, chisel and files Striking tools:
These tools are use to strike the job. These type of tool are hammer. I have seen these hammers in DLW fitting shop Ball peen hammer, straight peen hammer, cross peen hammer. Marking tools:
These tools are use for marking the job. I have seen in DLW fitting shop theses marking tool Scriber, Divider and Center Punch.
2.2 Mach Machine ine Shop Shop
12 Second week I have seen machine in diesel locomotive works (DLW). Machine shop is inside the Technical Training Center (TTC). Where workers and student are learns basic thing thing about about the machine machine which which is use use to make make diesel diesel locomotive locomotive works works (DLW). (DLW). I have seen following machine in the machine shop •
Lathe Machine: The lathe is used for producing cylindrical work. The
work piece is rotated while the cutting tool movement is controlled by the machine. •
Shaper Machine: Shaper is a machine used for the production of flat
surfaces in vertical, horizontal, or angular planes. •
Drilling Machine: A machine designed to hold drill bits which will
produce produce cylindrical cylindrical holes. holes. •
Milling Machine: A milling machine uses a rotating tool to produce
flat surfaces. A very flexible, light-duty machine. •
Grinding Machine: Grinding is a cutting technique used when close
tolerances and very smooth finishes are required. •
CNC Machine: The automation of machine tools that are operated by
abstractly programmed commands encoded on a storage medium, as opposed to controlled manually via hand wheels or levers, or mechanically automated via cams alone. These are CNC operation contour milling, face milling, slot and keyway cutting, template drilling, reaming, and boring.
Operation: Following operation I have seen in DLW
13 1. Turning operation: In this operation shaft is make circular and cylindrical. This is done on center lathe 2. Facing operation: Facing is a lathe operation in which the cutting tool removes metal from the end of the work piece. 3. Boring: Boring is an operation to enlarge and finish holes accurately. This may be done done on a lathe or a milling machine. machine. 4. Drilling operation: Drilling is an economical way of removing large amounts of metal to create semi-precision round hole or cavity. 5. Grinding operation: Grinding is an operation in which the cutting is done by the use of abrasive particles. 6. Shaping: Shaping is an operation used to produce flat surfaces.
2.3 Loco Assemb Assembly ly Shop (LAS) (LAS)
Fourth week I have seen LAS (Loco Assembly Shop). In LAS I have seen there are step by step process for for the assembled assembled the the locomotive locomotive.. There is is a sequence sequence for assemble. assemble. In LAS Electrical control equipment is fitted and control cable harnessing is undertaken. The complete locomotive is thus assembled before being sent onwards for final testing and spray painting. 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.
Operation in LAS:
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1. Driv Drivee cap cap ass assem embl bly y Air compressor assembly Control stand assembly 2. Driv Driver er cap cap che check ckin ing g Air brake piping 3. Long Long hood hood asse assemb mbly ly Buffer assembly Radiator setting 4. Eng Engine ine sett settin ing g Compressor setting 5. Long Long hood hood sett settin ing g Auxiliary generator assembly and setting Alternator part packing and assembly 6. Equi Equipm pmen entt asse assemb mbly ly Fuel oil parking Lube oil piping Engine water cooling piping 7. Driv Driver er shee sheett sett settin ing g Damper assembly Air duct setting
2.4 Heavy Welding Shop (HWS)
15 Third week I have heavy welding shop (HWS). Heavy welding shop (HWS) is inside the shop floor. There is all shop of manufacturing process. In heavy welding shop (HWS) there are made 16 cylinder V block engine. This engine is made by fabrication. I have seen following things in HWS. Different welding proses in HWS: •
Flame Cutting of Components: I have seen flame cutting in the HWS. Steel
plates of sizes up to 80 mm thickness thickness are ultrasonically ultrasonically tested tested before being precision cut by numerically numerically controlled controlled flame flame cutting cutting machines, machines, Plasma Plasma Cutting Cutting Machine.
•
Gas Welding: In gas welding I have seen Gas Metal Arc Welding (GMAW). In
gas metal arc welding they use inert gas for resist corrosion effect and wire of mild steel (MS). •
Submerged Arc Welding: In HWS I have seen submerged Arc Welding. In
submerged Arc Welding Lincoln Electric Flux is used. This flux is used to resist the corrosion effect.
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•
Fabrication of V Block engine:
1. Saddle: Saddle is a base on which other sheets are joined by fabrication. First of all they take saddle. Saddle used in the ALCO engine. Saddle has three types. •
Intermediate saddle: 7 intermediate saddles is use in ALCO engine. It width is 4.5”.
•
Centre saddle: 1 centre saddle is use in ALCO engine. It width is 6.75”.
•
T saddle: 1 T saddle is use in ALCO engine. It width is 4.625”.
Total number of saddle used is 9 in ALCO engine. 2. Second operation operation is joined joined the foundat foundation ion plate at saddle. saddle. 2 foundation foundation plates are joined at saddle. One is left side and other is right side. 3. Third operation operation is spline spline Joined Joined at saddle. 1 spline spline is joined joined at saddle. saddle. 4. Fourth operation operation is joined joined outside outside wall. wall. 2 outside outside wall wall are joined. joined. One is left side and other is right side.
17 5. This operation operation is joined 2 middle middle deck deck centre. centre. One is left left side and and other other is right right side. It width is 40 mm. 6. This operation operation is joined 2 in side side wall. wall. One is left side and and other other is right side. It width is 20 mm. 7. This operation operation is joined 2 top top Deck. One is left left side and and other other is right right side. 8. This This operati operation on is maki making ng water water comp comport ortmen ment. t. 9. This This opera operation tion is joined joined side side sheet sheet.. 10. This operation operation is joined joined end plate. 11. This operation operation is making making fuel fuel self. 12. This operation operation is joined top top deck centre. centre.
2.5 Rotor Shop (RS)
Fifth week I have seen Rotor Shop (RS). This shop is deals with the manufacturing of Turbocharger. Turbocharger is known as the Heart of Diesel Locomotive. Basically in this section manufacturing of assembly & sub assembly of Turbocharger is made. But the outer casing of Turbocharger is made up in Heavy Machine Shop. Turbocharger is use for the providing fresh air to the engine. Due to this the efficiency & power generated by engine is increased. For the running of Turbocharger we are not using any extra energy source like generator, motor etc. For starting of Turbocharger generally we use exhaust gasses.
Components of Turbocharger:-Turbocharger:--
For assembly of Turbojet following parts are manufactures in rotor shop---1. Impeller
18 2. Inducer 3. Nose piece 4. Stud Rotor 5. Nut 6. Washer 7. Thrust Washer 8. Key 9. Oil Slinger 10. Turbine Disc 11. Turbo Shaft 12. Lock plate
Assembly of Turbocharger:-Turbocharger:--
The assembly of turbocharger is done by dividing whole turbocharger in three parts. These are as follows---1. Rotor 2. Compressor 3. Casing 1. Rotor:--
Rotor is the inlet part of turbocharger which is comprises with following parts. Turbo Disc, 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:--
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. 3. Casing:--
19 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.
Working of Turbocharger:-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 018000rpm. It will be 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. SALIENT FEATURE OF G.M. MOTOR TURBOCHARGER 1. No. per per engine—1 engine—1 2. Stages—Single stage 3. Drive—Mechanical drive as well as exhaust gas gas driven with ver running clutch. 4. Air Flow—6.35kg/s
(Rated O/P) 5. Efficiency (At match pt.)-•
Turbine—87.2%
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•
compressor—81.5%
•
Mechanical—87.8%
6. Temperature for which critical components are designed— •
Compressor Stage— --Air temperature up to 190.6°C
•
Turbine stage---Gas temperature up to 593.3°C --Gas temperature up to 482.2°C on outlet side.
7. Pressure Ratio of Compressor –2.8 8. Temp. (Charge air after compressor)-- 171°C 9. Speed of Turbo (At rated O/P)—18,950rpm
2.6
Truck Machine Shop (TMS)
Sixth week I have seen 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
•
Bo-Bo 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 Manufacturing of bogie: There are two of manufactured bogies
1.
Fabricated bogie
2.
Casting bogie
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.
21 Important parts of bogie:
1.
Bogie frame: A bogie is a wheeled wagon or trolley. In mechanics terms, a
bogie is is a chassis or framework framework carrying carrying wheels, wheels, attached attached to a vehicle. vehicle.
Bogie 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 wheel and Bo-Bo Bo-Bo has two axles and and four wheel.
2.
Axle: EMD engine axle has three hole but in ALCO engine axle has eight
holes. 3.
wheels
4.
Bull gear
5.
suspension tube
6.
axle boxes
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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 3. Reason Reason for for choo choosing sing this this traini training ng
I choose Diesel Locomotive Works (DLW) for summer vocational training because •
It is the department of Indian Railways.
•
It is only in India which manufactured Diesel Locomotive.
•
It is ISO-9001, ISO14001 and OHS 18001 certified.
•
DLW high production rate 250 locomotive per year.
•
In Diesel Locomotive Works (DLW) there are many heavy and advance machines like Portal milling machine, Angular boring machine, CNC machine etc.
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•
In Diesel Locomotive Works (DLW) there are high and advanced welding technics like Submerged Arc Welding, Forging welding, Gas Metal Arc Welding and etc.
•
Diesel Locomotive Works (DLW) exports their products to other country like Shri Lanka, Angola, Vietnam, Tanzania, Bangladesh & Malaysia.
•
They making Diesel engine of two types EMD and ALCO. One two stroke and other is four stroke. So we can no common difference between them.
•
We can know about diesel engine and its firing orde.
4. Learning Outcome from training:
4.1.Nomenclature of diesel locomotive:
The first letter (gauge)
1. W-Indian W-Indian broad broad gauge gauge (The (The "W" Stands for Wide Wide Gauge Gauge - 5 Feet) Feet) 2. Y-metre Y-metre gaug gaugee (The "Y" "Y" stands stands for Yard Yard Gauge Gauge - 3 Feet) Feet) 3. Z-nar Z-narro row w gau gauge ge(2 (2 ft ft 6 in) 4. N-na N-narr rrow ow gaug gaugee (2 ft) ft) The second letter (motive power) •
D-Diesel
•
C-DC electric (can run under DC traction only)
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•
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)
The third letter (job type)
1. G-goods 2. P-pa -passen senger 3. M-mixe M-mixed; d; both both goods goods and passeng passenger er 4. S-Used for shunting shunting (Also (Also known known as switching switching engines engines or switchers switchers in United states and some other countries) 5. U-Elect U-Electric ric multipl multiplee units units (used as commu commuters ters in city city suburbs) suburbs) 6. R-Ra -Railcars The forth 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)
4.2.Engine:
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. 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.
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4.3.Machine used in fabrication:
•
Flame cutting machine
•
Shearing machine
•
Bending machine
•
Drill machine
•
Welding machine
•
Press brake machine
4.4.Cylinder block’s machining:
Machine used for cylinder block machining: • • •
Planner machine Horizontal milling machine Angular boring machine
In the lecture I know know about cylinder block’s machining. After fabrication of cylinder block following following operation operation is doing doing
Operation5. Making Operation10. Machining, top deck, top dead center and side sheet. Operation15. Machining of Foundation Rail by Planner machine Operation20. Machining of End plate by Horizontal milling machine. Operation25. Drilling, tapping and reaming of different size of hole. Operation30. Boring of cylinder liner by angular boring machine. Operation35. Foundation rail drilling and tapping. Operaton40. Drilling and tapping of top dead center and top deck. Operation45. Drilling and tapping of side sheet. Operation50. Making serration in crank bore. Operation55. Assembly of main bearing cap. Operation60. Crank and cam boring by horizontal boring machine
26 Operation65. Crank bore honing. Operation70. Capping remove. Operation75. Check alignment.
4.5. Flow chart for loco testing:
5. Gantt ch chart
Shop/Week Lecture + Fitting shop Lecture + Machine shop Loco Assembly
1 Week
2 Week
3 Week
4 Week
5 Week
6 Week
27 Shop(LAS) Heavy Welding Shop(HWS) Rotor shop(RS) Truck Machine Shop(TMS)
6. Bibliography •
www.dlw.indianrailways.gov.in
•
http://trainweb.org/railworld/DLW/ http://www.scribd.com/doc/64559155/Report-on-Summer-Training-at-Dlw-
•
Varanasi •
http://www.scribd.com/doc/54456974/Summer-Traning-DLW-Report
•
http://www.scribd.com/doc/45187594/Summer-Training-Diesel-LocomotiveWorks-Ppt
