BABU BANARSI DAS NATIONAL INSTITUTE

OF TECHNOLOGY & MANAGEMENT,

LUCKNOW

A

INDUSTRIAL TRAINING REPORT

ON

DISEL LOCOMOTIVE WORKSHOP

SUBMITTED TO: SUBMITTED BY:

RAMENDRA Kr. VISEN HIMANSHU S. SINGH

(Sr. LECTURER) ROLL NO: 1105440044

B.Tech (MECHANICAL)

B. B. D. N. I. T. M.

DIESEL LOCOMOTIVE WORKSHOP

VARANSI

A

INDUSTRIAL TRAINING REPORT

ON

DISEL LOCOMOTIVE WORKSHOP

SUBMITTED TO: SUBMITTED BY:

RAMENDRA Kr. VISEN HIMANSHU S. SINGH

(Sr. LECTURER) ROLL NO: 1105440044

B.Tech (MECHANICAL)

B. B. D. N. I. T. M.

ACKNOWLEDGEMENT

I take this opportunity my sincere thanks and deep gratitude to S.P. ASTHANA (HEAD OF MECHANICAL DEPARTMENT) all these people who extended their whole hearted co-operation and helped me in completing this project successfully.

First of all I would like to thanks all the S.S.E. and J.E. of the all the sections for creating oppurtunities to undertake me in this esteemed organization. Special thanks to all the department for all the help and guidance extended to me by them in every stage during my training. His inspiring suggestions and timely guidance enabled me to perceive the various aspects of the project in the new light.

In all I found a congenial work environment in DIESEL LOCOMOTIVE WORKSHOP, VARANSI and this completion of the project will mark a new beginning for me in the coming days.

SUBMITTED TO: SUBMITTED BY:

RAMENDRA Kr. VISEN HIMANSHU S. SINGH

(Sr. LECTURER) ROLL NO: 1105440044

B.TECH (MECHANICAL)

B. B. D. N. I. T. M.

INTRODUCTION

OF

INDIAN RAILWAY

Indian Railways is the state-owned railway company of India. It comes under the Ministry of Railways. Indian Railways has one of the largest and busiest rail networks in the world, transporting over 18 million passengers and more than 2 million tonnes of freight daily. Its revenue is Rs.107.66 billion. It is the world's largest commercial employer, with more than 1.4 million employees. It operates rail transport on 6,909 stations over a total route length of more than 63,327 kilometers(39,350 miles).The fleet of Indian railway includes over 200,000 (freight) wagons, 50,000 coaches and 8,000 locomotives. It also owns locomotive and coach production facilities. It was founded in 1853 under the East India Company.

Indian Railways is administered by the Railway Board. Indian Railways is divided into 16 zones. Each zone railway is made up of a certain number of divisions. There are a total of sixty-seven divisions.It also operates the Kolkata metro. There are six manufacturing plants of the Indian Railways. The total length of track used by Indian Railways is about 108,805 km (67,608 mi) while the total route length of the network is 63,465 km (39,435 mi). About 40% of the total track kilometer is electrified & almost all electrified sections use 25,000 V AC. Indian railways uses four rail track gauges

Indian Railways operates about 9,000 passenger trains and transports 18 million passengers daily .Indian Railways makes 70% of its revenues and most of its profits from the freight sector, and uses these profits to cross-subsidies the loss-making passenger sector. The Rajdhani Express and Shatabdi Express are the fastest trains of India.

INTRODUCTION

TO

DIESEL LOCOMOTIVE WORKSHOP

Diesel locomotive works is a production unit under the ministry of railways. This was set up in collaboration with American locomotive company (ALCO) USA in 1961 and the first locomotive was rolled out in 1964 .This unit produce diesel electronic locomotives and DG sets for Indian railways and other customers in India and abroad.

Subsequently a contract for transfer of technology of 4000 HP microprocessors controlled AC/AC freight (GT 46 MAC)/passenger (GT 46 PAC) locomotives and family of 710 engines has been signed with electromotive division of general motor of USA for manufacture in DLW . The production of this locomotive has now started and thus DLW is only manufacture diesel electric locomotives with both ALCO and general motor technologies in the world.

BRIFF HISTORY OF DLW

Diesel electric locomotives were introduced on Indian Railways in 1950’s to exploit their versatile y, better hauling capabilities, low maintenance requirement and cost effectiveness is compared to the steam locomotives.

DIESEL LOCOMOTIVE WORK was established in 1961 in collaboration with M/s ALCO,USA in t5he ancient temple city of Varanasi is undertake indigenous manufacture of diesel locomotives and meet the increased transportation needs of Indian railways over the year.

DLW’s production has progressively increased and it produced 164 locomotives, the highest number ever in the year 1997-98 as against 4 locomotives produced in the first year of its production in 1963-64 presently the locomotives are almost fully indigenous the import comet of the locomotives has come down from 98% in 63-64 to less then 5% as at present through in house development efforts, the original imported dowsing has been made 79 mare fuel-efficient and has axon been successfully up rated to deliver about 30% mere power.

By end of March’2005 DLW has manufactured 4707 locomotives and 39 high capacities dies generating sets. This includes 321 locomotives for non railways customers is India like power plants port trusts/steel plant etc. And 75 locomotives export to TANZANIA.VIETNAM.SRI LANKA .and Bangladesh & Malaysia 36 ydm4 locomotives manufactured by DLW are also operating on lease in Malaysia.

In order to upgrade the technology and keep pace with latest, Indian railways entered into an agreement with M/s general motors, USA for transfer of technology for the manufacture of 4000 HP state-of-the-art, AC-AC, microprocessor controlled fuel efficient WDG4/WDP4 locomotives at DLW these locos are now under man facture at DLW the first indigenous,WDG4 freight loco, was manufactured in mar,2002 and the first passenger version,WDP4,in march30 with 50% indigenous content straightway.51 such locomotives have been manufactured so far indigenous content increased to 70%.

DLW got its first ISO certification in 1997.recently DLW has obtained the “integrated Quality and environment management system” certification based on ISO-9001 an ISO14001 indec.2002.DLW is proud to be the pioneer in this area amongst the government/public sector units in the country.

SALIENT FEATURE

Annual production capacity` 125 Locomotives

Annual turn-over (Rs) 5000 million

Total number of staff 7223

Workshop land 89 Hectares

Township area 211 Hectares

Covered area in shops 86300 Sq.m

Covered area of other Service buildings 73700 Sq.m

Electrical power requirement 3468 KVA (Average maximum demand)

Electrical energy consumption (units/year) 19.8 million

Stand by power generation capacity 3000 KW

DIFFERENT WORKS AT DLW

UNDER FRAMES & SUPERSTRUCTURES:

Precision cutting and formatting of sheet metal is utilized for manufacture of superstructures including driver cab, engine hoods, and compartment for housing electric equipment. All activities connected with pipes like pickling, bending, cutting, forming and threading of pipes of various work area, all electrical equipment is assembled in the fabricated control compartment and driver’s control stands.

Under frames are fabricated taking all due care to ensure designed weld strength. Care is taken to impart the requisite camber to the under frame during fabrication it self. Wherever required, welds are tested radio graphically. Welder training and their technical competence is periodically reviewed

FIG NO 1( SUPER STRUCTURE OF ENGINE)

BOGIE MANUFACTURING:

Large special purpose machines are utilized for machining cast and fabricated bogie frames in the same work area, axel and wheel disc machining is undertaken on sophisticated CNC machines. Inner diameter of wheels discs are carefully matched with the outer diameter of. Axles before the wheel discs are pressed onto, at designated pressure, using a specially designed wheel press. The complete truck (bogie), including bogie frames, wheels and axles, brake rigging and traction motor is assemble d before being sent onwards for locomotive assembly.

FIG NO 2 ( BOGIE)

LOCOMOTIVE ASSEMBLY AND TESTING:

Assembled and tested engines are received in this shop from Engine Division. Also , under frame , assembled truck , superstructures and contractor compartment are receive from respective manufacturing and assembly shops of Vehicle Division. Important alignments like crank shaft deflection, compressor alignment like crank shaft deflection, compressor alignment and Eddy Current clutch/radiator fan alignment are done during assembly stage if self.

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.

Rigorous testing of all locomotive system is conducted as per laid down test procedures before the locomotives is taken up for final painting and dispatch.

The engine block, crankshaft, camshaft, cylinder liners, pistons, connecting rods, cylinder heads, exhaust manifold, turbo-supercharger and all related piping is assembled to make a complete engine. This is followed by mounting of electrical machines like traction alternator, auxiliary generator and exacter. This power pack is tested for horsepower output and other parameters of engine heath on computerized Engine test beds. Only after the engine parameters are found perfect the power pack is allowed to be moved to the locomotives assembly area.

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 .all locomotive systems are rigorous tested as per laid down test procedures before the locomotive is taken up for final painting and dispatch.

CLASSIFICATION

1. Standard “Gauge” designations and dimensions:- W = Broad gauge (1.67 m) Y = Medium gauge ( 1 m) Z = Narrow gauge ( 0.762 m) N = Narrow gauge ( 0.610 m)

2. “ Type of Traction” designations:- D = Diesel-electric traction C = DC traction A = AC traction CA=Dual power AC/DC traction

3. The “ type of load” or “Service” designations:- M= Mixed service P = Passenger G= Goods S = Shunting

4. “ Horse power ” designations from June 2002 (except WDP-1 & WDM-2 LOCOS)

‘ 3 ’ For 3000 horsepower ‘ 4 ’ For 4000 horsepower ‘ 5 ’ For 5000 horsepower ‘ A ’ For extra 100 horsepower ‘B’ For extra 200 horsepower and so on

.

Hence ‘WDM-3A’ indicates a broad gauge loco with diesel-electric traction. It is for mixed services and has 3100 horsepower.

OVERVIEW OF DIESEL LOCOMOTIVE

FIG NO 3 ( OVERVIEW OF LOCOMOTIVE)

SAND BOX

RADIATORRADIATOR FAN TURBO SUPERCHARGERBOGIE(2 SETS)(3AXLE OR 2 AXLE)

FUEL TANK AIR RESERVOIERSPOWER PACK

DYNAMO WITH ALTRNATORBATTERIESDRIVER CABIN WHEEL ASSEMBLYDISC BLOWER TRACTON MOTERTRUCKGEAR AND PENION ASSSEMBLYCYLINDER HEADCROSS HEAD FUEL INJECTION PUMPBATTERIES (8 OF 8.68 VOLTS)FUEL TANK AFTER COOLING CORE JUNCTION BOX

PRODUCTION SHOPS

There are three production shops:

1. BLOCK DIVISION2. ENGINE DIVISION3. LOCO DIVISION

BLOCK DIVISION

There are two block division

1. HEAVY WELD SHOP2. HEAVY MACHINE SHOP

ENGINE DIVISION

There are seven engine division

1. ENGINE ERECTION SHOP2. ENGINE TESTING SHOP3. LIGHT MACHINE SHOP4. SUB ASSEMBLY SHOP5. ROTOR SHOP6. HEAT TREATMENT SHOP7. TURBO SELECTION SHOP

LOCO DIVISION

There are eight loco division:

1. LOCO FRAME SHOP2. PIPE SHOP3. TRUCK MACHINE SHOP4. TRACTION ASSEMBLY SHOP5. SHEET MEATL SHOP6. LOCO AASEMBLY SHOP7. LOCO PAINT SHOP8. LOCO TEST SHOP

SUB ASSEMBLY SHOP

This shop deals with following section:--

1.Turbo machining section

2.Cylinder head & shot blast section

3.Fuel pump, Support, Cam shaft ate section

4.Cylinder head

5.Turbo

6.Governor, Water Pump, Fan drive, Lube oil Pump, After cooler assembly section.

CYLINDER HEAD SECTION

The lay out of this section is product type. There are different machines had do set up per sequence of operation of cylinder head.

A milling machine provides profile cutting and taper profile according of the template. The tracer runs and cutter forms shaper radial drilling machine. This machine provides for drilling tapping. Core boring operation as per drawing

HEARALD BOROING MACHINE

This machine having four spindles for boring of guide hole, air & exhaust it dimensions are—

1.Valve inner sheet dia 4 hole- 3.1805-3.1815

2.Guide hole dia- 1.0625‖-1.0635‖

3.Valve sheet depth (E1, E2, A1)- 0.740‖ to 0.745‖ & A2- 0.950‖

4.Depth of sheet (A1 E1, E2)- 0.205‖-0.215‖

5.Spring sheet depth (E1, E2, E1)- 1.865‖-1.885

CONTROL SHAFT ASSEMBLY

It is a link between Governor & Fuel injector pumps by which the mechanical power from the governor transmitted to the fuel injection pump Racks. It means to control the amount of fuel according to the requirement of load & speed.

EXPLOSION DOOR COVER ASSEMBLY

. It is special type of main base door cover which when the crank case exhauster failed to work

CAM SHAFT VIBRATION DAMPER ASSEMBLY

When vibration developed on the cam shaft will be damped by this assembly.

O.S.T. HOUSING ASSEMBLY

This assembly controls the R.P.M. of crank shaft and keeps it a specified limit (1000 to 11500 r.p.m.). When OST is operated in the case 16 cylinder engine the engine RPM will come in ideal but in case of 16 cylinder engines will be stopped.

FUEL PUMP SUPPORT ASSEMBLY

It is a support of the fuel pump on which the fuel injection pump is mounted and the power of cam shaft is transmitted to operate fuel injection pump through the cross head lighter & to operate push rod by PRD. Lifter by which the inlet & exhaust valve open & closed through the valve lever & yokes.

ACCELERATION CONTROL DEVICE

By this device by monopoly of the driver is controlled the air & fuel supply is controlled by according to the fuel ratio. It is controlled the proper fuel and air ratio.

FIG NO 4(Schematic diagram of ALCO Engine)

ROTOR SHOPThis 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

For assembly of Turbojet following parts are manufactures in rotor shop

1. Impeller 7. Thrust Washer

2. Inducer 8. Key

3. Nose piece 9. Oil Slinger

4. Stud Rotor 10. Turbine Disc

5. Nut 11. Turbo Shaft

6. Washer 12. Lock plate

ASSEMBLY OF TURBOCHARGER

The assembly of turbocharger is done by dividing whole turbocharger in three parts. These are as follows

1. Rotor

2. Compressor

3. Casing

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 is the combination of impeller & inducer. Impeller is made up of Al-alloy. Impeller & inducer is use for sucking of fresh air from environment

. FIG NO (5) TURBOSUPER CHRAGER

3. CASING

Casing is made of M.S. & also a special type of coating is done. Due to that coating it can easily resist the heat.

For the proper working & life of Turbocharger balancing of impeller, inducer & turbine disc is done by help of Dynamics Balancing Machine.

For the proper working & life of Turbocharger balancing of impeller, inducer & turbine disc is done by help of Dynamics Balancing Machine.

TURBO SUPERCHARGER AND ITS WORKING

PRINCIPLE

The exhaust gas discharge from all the cylinders accumulate in the common exhaust manifold at the end of which, turbo- supercharger is fitted. The gas under pressure there after enters the turbo- supercharger through the torpedo shaped bell mouth connector and then passes through the fixed nozzle ring. Then it is directed on the turbine blades at increased pressure and at the most suitable angle to achieve rotary motion of the turbine at maximum efficiency. After rotating the turbine, the exhaust gas goes out to the atmosphere through the exhaust chimney.

The turbine has a centrifugal blower mounted at the other end of the same shaft and the rotation of the turbine drives the blower at the same speed. The blower connected to the atmosphere through a set of oil bath filters, sucks air from atmosphere, and delivers at higher velocity. The air then passes through the diffuser inside the turbo- supercharger, where the velocity is diffused to increase the pressure of air before it is delivered from the turbo- supercharger

Pressurising air increases its density, but due to compression heat develops. It causes expansion and reduces the density. This effects supply of high-density air to the engine. To take care of this, air is passed through a heat exchanger known as after cooler. The after cooler is a radiator, where cooling water of lower temperature is circulated through the tubes and around the tubes air passes. The heat in the air is thus transferred to the cooling water and air regains its lost density. From the after cooler air goes to a common inlet manifold connected to each cylinder head. In the suction stroke as soon as the inlet valve opens the booster air of higher pressure density rushes into the cylinder completing the process of super charging.

The engine initially starts as naturally aspirated engine. With the increased quantity of fuel injection increases the exhaust gas pressure on the turbine. Thus the self-adjusting system maintains a proper air and fuel ratio under all speed and load conditions of the engine on its own. The maximum rotational speed of the turbine is 18000/22000 rpm for the Turbo supercharger and creates max. Of 1.8 kg/cm2 air pressure in air manifold of diesel engine, known as Booster Air Pressure (BAP). Low booster pressure causes black smoke due to incomplete combustion of fuel. High exhaust gas temperature due to after burning of fuel may result in considerable damage to the turbo supercharger and other component in the engine.

FIG NO(6)TURBOSUPERCHRGER WORKING

EXPRESSOR

FIG NO (7) EXPRESSOR

In Indian Railways, the trains normally work on vacuum brakes and the diesel locos on air brakes. As such provision has been made on every diesel loco for both vacuum and compressed air for operation of the system as a combination brake system for simultaneous application on locomotive and train.

In ALCO locos the exhauster and the compressor are combined into one unit and it is known as EXPRESSOR. It creates 23" of vacuum in the train pipe and 140 PSI air pressure in the reservoir for operating the brake system and use in the control system etc.

The expressor is located at the free end of the engine block and driven through the extension shaft attached to the engine crank shaft. The two are coupled together by fast coupling (Kopper's coupling). Naturally the expressor crank shaft has eight speeds like the engine crank shaft. There are two types of expressor are, 6CD,4UC & 6CD,3UC. In 6CD,4UC expressor there are six cylinder and four exhauster whereas 6CD,3UC contain six cylinder and three exhauster.

WORKING OF EXHAUSTER

Air from vacuum train pipe is drawn into the exhauster cylinders through the open inlet valves in the cylinder heads during its suction stroke. Each of the exhauster cylinders has one or two inlet valves and two discharge valves in the cylinder head. A study of the inlet and discharge valves as given in a separate diagram would indicate that individual components like

(1) plate valve outer

(2) plate valve inner

(3) spring outer

(4) spring inner etc. are all interchangeable parts.

Only basic difference is that they are arranged in the reverse manner in the valve assemblies which may also have different size and shape. The retainer stud in both the assemblies must project upward to avoid hitting the piston.

The pressure differential between the available pressure in the vacuum train pipe and inside the exhauster cylinder opens the inlet valve and air is drawn into the cylinder from train pipe during suction stroke. In the next stroke of the piston the air is compressed and forced out through the discharge valve while the inlet valve remains closed. The differential air pressure also automatically open or close the discharge valves, the same way as the inlet valves operate. This process of suction of air from the train pipe continues to create required amount of vacuum and discharge the same air to atmosphere. The VA-1 control valve helps in maintaining the vacuum to requisite level despite continued working of the exhauster.

COMPRESSOR

The compressor is a two stage compressor with one low pressure cylinder and one high pressure cylinder. During the first stage of compression it is done in the low pressure cylinder where suction is through a wire mesh filter. After compression in the LP cylinder air is delivered into the discharge manifold at a pressure of 30 / 35 PSI.

Workings of the inlet and exhaust valves are similar to that of exhauster which automatically open or close under differential air pressure. For inter-cooling air is then passed through a radiator known as inter-cooler. This is an air to air cooler where compressed air passes through the element tubes and cool atmospheric air is blown on the out side fins by a fan fitted on the expressor crank shaft. .

A safety valve known as inter cooler safety valve set at 60 PSI is provided after the inter cooler as a protection against high pressure developing in the after cooler due to defect of valves.

After the first stage of compression and after-cooling the air is again compressed in a cylinder of smaller diameter to increase the pressure to 135-140 PSI in the same way. This is the second stage of compression in the HP cylinder. Air again needs cooling before it is finally sent to the air reservoir and this is done while the air passes through a set of coiled tubes after cooler.

LOCMOTIVE /TRUCK

MACHINE SHOP

FIG NO (7)TRUCK MACHINE SHOP

FABRICATION OF ENGINE BLOCK

Steel plates of sizes up to 80 mm thick are ultrasonically tested before being precision cut by numerically controlled flame cutting machines. Fabrication of engine block is completed by submerged arc welding using semi-automatic welding machines. Down-hand welding is ensured using specially designed petitioners. 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 job

FIG NO (8) FABRICATION OF ENGINE BLOCK

MACHINING OF ENGINE BLOCK

The fabricated engine block is then taken up for a variety of machining operations like planning, enveloping and end drilling. All these operations use heavy duty planers and CNC drilling machines. V-boring of cylinder liner bores is a process requiring a high degree of precision and is undertaken using a specially designed machine. Recent addition of a Plano-milling centre has provided further fillip to the quality and speed of enveloping operation. 12 Cylinder and 16 Cylinder Blocks have V angle of 45°, whereas the 6 Cylinder Block is inline type.

FIG NO (9) TESTING OF THE LOCOMOTIVE OR TRUCK

COMPONENT MANUFACTURING

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 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. All related 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.

FIG NO(10) COMPONENT MANUFACTURING

ENGINE ASSEMBLY & TESTING

The engine block, crankshaft, camshafts, cylinder liners, pistons,

connecting rods, cylinder heads, exhaust manifold, turbo-supercharger and all related piping is assembled to make a complete engine. This is followed by mounting of electrical machines like traction alternator, auxiliary generator and exciter. This power pack is tested for horsepower output and other parameters of engine health on computerized Engine Test Beds. Only after the engine parameters are found perfect the power pack is allowed to be moved to the locomotive assembly area

FIG NO(11)ASSEMBLED ENGINE

VEHICLE DIVISION

UNDERFRAMES & SUPERSTRUCTURES

FIG NO (12) SUPERSTRUCTURE

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. In yet another work area, all electrical equipment is assembled in the fabricated control compartments and driver’s control stands. Under frames are fabricated taking all due care to ensure designed weld strength. Care is taken to impart the requisite camber to the under frame during fabrication itself. Wherever required, welds are tested radio graphically. Welder training and their technical competence is periodically reviewed.

BOGIE MANUFACTURING

FIG NO (13) BOGIE MANUFACTURING

Large special purpose machines are utilized for machining cast and fabricated bogie frames. In the same work area, axle and wheel disc machining is undertaken on sophisticated CNC machines. Inner diameter of wheel discs are carefully matched with the outer diameter of axles before the wheel discs are pressed onto axles, at designated pressure, using a specially designed wheel press. The complete truck (bogie), including bogie frames, wheels and axles, brake rigging and traction motors is assembled before being sent onwards for locomotive assembly.

LOCOMOTIVE ASSEMBLY & TESTING

FIG NO(14) ENGINE TESTING

Assembled and tested engines are receive in this Shop from Engine Division. Also, under frames, assembled trucks, superstructures and contractor compartments 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 itself. 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. Rigorous testing of all locomotive systems is conducted as per laid down test procedures before the locomotive is taken up for final painting and dispatch.

MACHINE SHOP

There are some important machines which used in the different type of shops.

1. LATHE MACHINE

2. SLOTTER MACHINE

3.PLANER MACHINE

4.CNC WHEEL SURFACE LATHE

5.CNC WHEEL TURRET LATHE

6.CNC BIG BORE LATHE WITH SPINDLE

CONCLUSION

I have completed my training from the DIESEL LOCOMOTIVE WORKSHOP , VARANSI . I have observed many shop in the workshop I mainly performed my training in the the LAS, SAS , ROTOR SHOP AND TMS SHOP.

In the locomotive workshop ,all the SSE and JE and SUPERVISIORS of all te shops helped very much. Without hisor her supervision I was not able to perform the training in all the workshops. I am very grateful to him .

We have learned too much in the workshop, DIFFERENT TYPE OF WORKSHOP TECHNOLOGY, TESTING OF THE PARTS OF THE LOCOMOTIVE AND THE PROPER FUNCTIONING of the different locomotive parts as a TURBOSUPERCHARGER, EXPRESSOR, POWER PACK OF THE LOCOMOTVE , RADIATOR SECTION ,OIL SUMP, DYNAMO AND BOGIE AND FABRICATION OF THE BODY OF LOCOMOTIVE .

REFRENCES

Workshop technology by Hazara & Chaudhary Production technology by P.C. SHARMA Study material provided by TECHNICAL TRAINING CENTRE Workshop technology by S. K. GARG WWW.RAILWAY TECHNICAL.CO.IN WWW.HOWSTUFFWORKS.IN WWW.IRFCA.CO.IN