1

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 DEVBARAT SINGH

(Sr. LECTURER) ROLL NO: 1105440035

B.TECH (MECHANICAL)

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

2

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.

3

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.

4

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.

5

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.

6

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

7

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)

8

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)

9

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.

10

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.

11

OVERVIEW OF DIESEL

LOCOMOTIVE

FIG NO 3 ( OVERVIEW OF LOCOMOTIVE)

SAND BOX

RADIATOR

RADIATOR FAN

TURBO SUPERCHARGER

BOGIE(2 SETS)(3AXLE OR 2 AXLE)

12

FUEL TANK

AIR RESERVOIERS

POWER PACK

DYNAMO WITH ALTRNATOR

BATTERIES

DRIVER CABIN

WHEEL ASSEMBLY

DISC

BLOWER

TRACTON MOTER

TRUCK

GEAR AND PENION ASSSEMBLY

CYLINDER HEAD

CROSS HEAD

FUEL INJECTION PUMP

BATTERIES (8 OF 8.68 VOLTS)

FUEL TANK

AFTER COOLING CORE

JUNCTION BOX

13

PRODUCTION SHOPS

There are three production shops:

1. BLOCK DIVISION

2. ENGINE DIVISION

3. LOCO DIVISION

BLOCK DIVISION

There are two block division

1. HEAVY WELD SHOP

2. HEAVY MACHINE SHOP

ENGINE DIVISION

There are seven engine division

1. ENGINE ERECTION SHOP

2. ENGINE TESTING SHOP

3. LIGHT MACHINE SHOP

4. SUB ASSEMBLY SHOP

5. ROTOR SHOP

6. HEAT TREATMENT SHOP

7. TURBO SELECTION SHOP

14

LOCO DIVISION

There are eight loco division:

1. LOCO FRAME SHOP

2. PIPE SHOP

3. TRUCK MACHINE SHOP

4. TRACTION ASSEMBLY SHOP

5. SHEET MEATL SHOP

6. LOCO AASEMBLY SHOP

7. LOCO PAINT SHOP

8. LOCO TEST SHOP

15

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

16

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.

17

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)

18

ROTOR SHOP

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

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

19

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

20

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

21

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

22

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.

23

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.

24

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.

25

LOCMOTIVE /TRUCK

MACHINE SHOP

FIG NO (7)TRUCK MACHINE SHOP

26

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

27

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

28

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

29

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

30

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.

31

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.

32

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.

33

MACHINE SHOP

There are some important machines which used in the different

type of shops.

1. LATHE MACHINE

34

2. SLOTTER MACHINE

3.PLANER MACHINE

35

4.CNC WHEEL SURFACE LATHE

5.CNC WHEEL TURRET LATHE

36

6.CNC BIG BORE LATHE WITH SPINDLE

37

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 .

38

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