VOCATIONAL TRAINING REPORT

DIESEL LOCOMOTIVE WORKS (DLW)VARANASI

BY ANUPAM SINGH 4TH YEAR (ME)

SRMGPC

DLW was founded by 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 diesel- electric 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 late, on January 3, 1964. It manufactures locomotives.

HISTORY OF DLW:-

DLW IS A production unit under the ministry of railway, it is one of the factories in the world which can be called diesel locomotive manufacturing plant .It had made over 2000 component s are manufactured.

Set up in 1961 technical collaboration with ALCO of USA for manufacture of diesel electric locomotive .

In 1995 , Indian railway entered into an agreement with general motors ,USA is transfer this technology for manufacture of 4000hp microprocessor controller.Got its first ISO certification in 1997 and ISO-9001 and ISO-14001 in December 2002.

At present the locomotive produced by DLW; i.e. GM engine has capacity up to 5000HP & try to make it 5500 HP.

It has supplied locomotive to other countries such as Sri lanka , Bangladesh , Malaysia, Vietnam etc.

DLW is supplied locos to PSU’s & Industries like NTPC , coal , INDOGULF etc.

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 locomotives

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……..

DLW’S annul Production -275 Component are manufacture -2000 component Cost of one LOCO -25 crore(EMD) -15 crore (ALCO) Weight of one LOCO -121 ton Fuel consumption at full load -540 lit/hr Fuel consumption at idle load -40 lit/hr Max. Speed -160km/hr Dia. of wheel -1092mm

Facts about Diesel-Electric Locomotives:-

1) BLOCK DIVISIONS2) ENGINE DIVISIONS3) LOCO DIVISIONS

1. Heavy Weld Shop1) BLOCK DIVISIONS2) ENGINE DIVISIONS3) LOCO DIVISIONS

BLOCK DIVISIONS 1. Heavy Weld Shop2. Heavy Machine Shop3. Heavy Machine Shop

PRODUCTION SHOPS

My four week training was confined to four different section

CMT LAB ENGINE TESTING SHOP

LOCO TEST SHOP IRWRI

It is known as a chemical metallurgy lab.

Qualitative inspection of raw materials which is purchased from outside and which should be manufactured in the workshop.

Chemical analysis of ferrous and non ferrous materials.

Metallurgical analysis of defective components.

CMT LAB:-

CMT LAB:-

Welding 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.

WELDING shop

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

DLW

LOCO AND ENGINE TEST SHOP:-

Lubricating oil testing:- Lubrication is done for the better

performance of the engine parts. Testing is done by the checking of

circulation of lubricant oil. Checking also for the returning

path of the lubricant oil not only for the forward path.

RR40 is used as a lubricant oil.

-:TYPES OF TESTING:-

Water testing:- Water act as a coolant for moving part of the engine because constant rotation or

movement cause various parts to heat up and water working as a coolant. Load testing:- For load testing electrical load is provided for the testing. If there is any abnormal

sound in the engine then it should be again tested for the lubrication and if there is any flaw in it should be removed.

LOCO TEST SHOP(LTS)

FINAL LOCO TEST

THANK YOU…..!!!!!