Summer training report on diesel locomotive works Varanasi Build the nation with welding TRAINEE AT DLW VARANASIPRAVEEN TIWARI ME-7.2ROLL NO- 1109040141IEC-CET, GREATER NOIDABuild the nation with welding DLW, was founded by Late Railway Minister Mr. Lal Bahadur Shastri on 23 April 1956. It is spread in 300 acres area at Varanasi.It is a production unit owned by Indian railways , for which it manufactures dieselelectric locomotives and its spares parts.To meet the increased transportation needs of the Indian railways it was established in collaboration with ALCO( American Locomotive Company), USA in 1961. DLW rolled out its first locomotive three years later, on January 3, 1964. It manufactures locomotives. Introduction Build the nation with welding Got its first ISO certification in 1997 and ISO-9001 and ISO-14001 in December 2002.With technology transfer agreement from manufacturers such as GM-EMD, DLW today produces advance locomotives having output range from 2600 to 4000 hp.At present the latest locomotive produced by DLW; i.e. WDG 5 has capacity upto 5000 HP & trying to make it 5500 HP.It has supplied locomotives to other countries such as Sri Lanka, Bangladesh, Malaysia, Tanzania and Vietnam etc.DLW is supplying locos to PSUs & Industries Like NTPC, COAL, INDOGULF etc.Build the nation with welding DLWs annual production - 250 LocoCost of one loco - 12 to 14 crore (EMD) 8 crore (Alco)Weight of one Loco - 121 TonFuel Consumption; At Full Load - 540 lt/hr. Idle Load - 40 lt/hr.Max. Speed - 160 Km/hr.Dia of Wheel - 1092 mmWheel to Wheel Distance - 1596.5 mm Length of Under Frame - 19962 mmsome facts about diesel electric locomotiveBuild the nation with welding In a diesel-electric locomotive, the diesel engine drives an electrical generator or alternator whose output provides power to the traction motors. There is no mechanical connection between the engine and the wheels. Diesel electric locomotiveBuild the nation with welding Locos, except the older steam ones, have classification codes that identify them. This code is of the form WDG5A [ gauge ][ power ][load ][ series ][ sub type ] The first letter (gauge) W- Indian broad gauge(5.6ft) Y- meter gauge (3.4ft) Z- narrow gauge(2.5 ft) N- narrow gauge (2 ft) The second letter (motive power) D- Diesel C- DC electric (can run under DC traction only) A- AC electric (can run under AC traction only) CA- Both DC and AC (can run under both AC and DC tractions) B- Battery electric locomotive (rare) Classification of locomotivesBuild the nation with welding The third letter (load type) G-goods P-passenger M-mixed traffic ; both goods and passenger S-Used for shunting U-Electric multiple units (E.M.U.) R-Railcars THE fourth letter (series) The series digit identifies the horsepower range of the locomotive. Example for the series letter 3 means that the locomotive has power over 3000 hp but less than 4000 hp. The fifth letter (subtype) An optional letter or number that indicates some smaller variations in the basic model. For ex: A for 100 hp, B for 200 hp and so on..Build the nation with welding 1. Block Divisions2. Engine Divisions3. Loco Divisions Production ShopsBlock Division 1. Heavy Weld Shop 2. Heavy Machine ShopBuild the nation with welding Engine Division1. Engine Erection Shop2. Engine Testing Shop3. Light Machine Shop4. Sub Assembly Shop5. Rotor Shop6. Heat Treatment Shop7. Turbo SectionBuild the nation with welding Build the nation with welding Build the nation with welding Loco Division1. Loco Frame Shop2. Pipe Shop3. Truck Machine Shop4. Traction Assembly Shop5. Sheet Metal Shop6. Loco Assembly Shop7. Loco Paint Shop8. Loco Test ShopBuild the nation with welding Build the nation with welding WELDING shopWelding is a process which produces joining of materials by heating them to suitable temperatures with or without the application of pressure and with or without the use of filler material. Welding is used for making permanent joints. It is used in the manufacturing of automobile bodies, aircraft frames, railway wagons, machine frames, structural works, tanks, furniture, boilers, general repair work and ship building.Build the nation with welding Shielded Metal Arc Welding [SMAW]Submerged Arc Welding [SAW]Gas Shielded Metal Arc Welding [MIG]Flux Cored Arc Welding [FCAW]Types Of Welding Used In DLWBuild the nation with welding Build the nation with welding *LASER CUTTING-UPTO 4MMBuild the nation with welding *UNDER WATER PLASMA CUTTING UPTO 16 MMBuild the nation with welding Build the nation with welding bogie assembly shopA bogie is a wheeled wagon or trolley. In mechanics terms, a bogie is a chassis or framework carrying wheels, attached to a vehicle. Usually the train floor is at a level above the bogies, but the floor of the car may be lower between bogies.Build the nation with welding Bogie Assembly (EMD)Wheel and Axle assembly.Brake rigging assembly.Traction motor & gear case assembly.Bearing adopter assembly.Final assembly. Axle, Wheel & Axle Box assemblyThese wheels are having wear adapted profile to RDSO drawing.Dead LeverLive LeverCylinder LeverBrake ShoeBrake HeadBrake Rigging ArrangementAxle, wheel & Gear assembly with Traction Motor Traction motor Electric motor providing the primary rotational torque of a machine, usually for conversion into linear motion.DC series-wound motors, running on approximately 600 volts. The availability of high-powered semiconductors such asthyristors has now made practical the use of much simpler, higher-reliabilityACinduction motors.Build the nation with welding PRESS BULL GEAR ON AXLE.SHIFT ABOVE ASSEMBLY AT BEARING HOUSING FITTING STAND.FIT THE BEARING HOUSING AND BOLTING .ASSEMBLE SEAL , CAP AND TAPER ROLLER BEARING BOLTING .NOW, SHIFT THIS ASSEMBLY ON WHEEL & AXLE PRESS MACHINE.ASSEMBLY PROCESS:Build the nation with welding Break down of machine can occur due to the following two reasons:Due to unpredictable failure of component which cannot be prevented.Due to gradual wear and tear of the parts of the machine which can be prevented by regular inspection known as preventive maintenance. Preventive maintenance Also termed as planned maintenance or systematic maintenance .An extremely important function for the reduction of the maintenance cost and to keep the good operational condition of equipment. Breakdown maintenance MAINTAINANCE AREABuild the nation with welding To obtain maximum availability of the plant by avoiding break down and by reducing shut down period to a maximum.To keep the machine in proper condition so as to maintain the quality of the product.To ensure the safety of the workers.To keep the plant at the maximum production efficiency.To achieve the above objectives with most economical combination.objective of preventive maintenanceBuild the nation with welding Heavy Machine ShopLight Machine ShopMACHINE SHOPBuild the nation with welding 1. Conventional machine2. NC machine3. CNC machine1. Conventional machine: It is a simple machine which is now an old technique. 2. Numerical control machine: Numerical control is defined as a system in which the actions of the machines are controlled by the insertion of the numerical data. In other words number controls the action. Types of machinesBuild the nation with welding machines in area B Flame cutting Steel plates are ultrasonically tested before being precision cut by numerically controlled flame cutting machines or by CNC LASER machine. CNC Laser cuttingThe laser beam is typically 0.2 mm (0.008 in) diameter at the cutting surface with a power of 1000 to 2000 watts.Lasers work best on materials such as carbon steel or stainless steels because these are difficult to cut due to their ability to reflect the light as well as absorb and conduct heat. This requires lasers that are more powerful.Build the nation with welding Angular Boring Machine This special purpose machine has two high precision angular boring bars.Boring bars are mounted on high precision bearings which provide control on size during angular boring. Fabrication of Engine Block Components after flame cutting and various machining operations are fit and tack welded before taking on rollovers. Heavy Argon-CO2 welding is done on these rolloversBuild the nation with welding CNC milling machinesCNC mills can perform the functions of drilling and often turning. CNC Mills are classified according to the number ofaxesthat they possess. A standard manuallight-duty millis typically assumed to have four axes:Table x.Table y.Table z.Milling Head z.Build the nation with welding LOCO & ENGINE TEST SHOPBuild the nation with welding Lubricating oil testing Lubrication is done for better performance of the engine parts. testing is done by checking the circulation of lubricant oil. For rotating parts checking is done by seeing the returning path of the oil i.e. checking not only the forward path but also the returning path. RR40 is used as lubricating oil.types of testingBuild the nation with welding 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. water testingBuild the nation with welding Base inspection under screen and fitting over screen.Water circulation.Lube oil filling and check deflection crank shaft.Lube oil circulation.Pre run on no load 3 to 5 times of duration 10 to 30 min each 400 rpm.Intermediate runs 12 runs of 30 min duration each from 400 to 1000 rpm. Engine test operation sequenceBuild the nation with welding Check over speed trip of recheck 3 times.Check bake in nozzles and set tapped clearance.Inspection before fist hour performance.First hour performance on full load.Base inspection.Second hour performance on full load. Attend defects of first hour performance.Final base inspection.Check engine deficiencies.Engine clearance.Build the nation with welding Transport sectionIn transport section there are basically two types of machine are used for transportation purpose of the different jobs from one shop to other.Different machines used are 1. fork lift truck 2. cranesBuild the nation with welding Fork lift truck Forklift is a powered industrialtruckused to lift andtransportmaterials. Build the nation with welding Truck Frame- is the base of the machine to which the mast, axles, wheels, counterweight, overhead guard and power source are attached.Cab- is the area that contains a seat for the operator along with the controlpedals,steering wheel,levers,switchesand a dashboard containing operator readouts.Overhead Guard- is a metalroofsupported by posts at each corner of the cab that helps protect the operator from any falling objects.Power Source- may consist of aninternal combustion engineor battery. Counterbalanced forklift componentsBuild the nation with welding HYDRAULIC LADDERBuild the nation with welding cranesAcraneis a lifting machine, generally equipped with awinder,wire ropesorchainsandsheaves, that can be used both to lift and lower materials and to move them horizontally.Build the nation with welding Build the nation with welding ***