A

SUMMER FIELD TRAINING REPORT

AT

DIESEL LOCOMOTIVE WORKS

VARANASI

Submitted To Faculty Of Engineering And Technology,

Chandra SekharAzad University Of Agriculture And Technology, Kanpur

In partial fulfillment of the requirement for the award of degree of

BACHELOR OF TECHNOLOGY

IN

MECHANICAL ENGINEERING

BY

SHAILESH SHUKLA

CT –1674/09

Baba Saheb Dr. Bhim Rao Ambedkar College Of Agricultural Engineering And

Technology, Etawah-206001

(Chandra Sekhar Azad University Of Agriculture And Technology, Kanpur)

ACKNOWLEDGEMENT

I would sincerely like to thank the employees and the officers of DLW,

VARANASI for their help and support during the vocational training.

Despite their busy schedules, they took time out for us and explained to

us the various aspects of theworking ofthe plant from the production

shops.

I would sincerely like to thank Mr. Sudhir Sinha (CWI /TTC) and Mr.

Ajay Kumar(JE/HWS), Mr. Vipin Srivastava(JE/HWS), Mr. Arvind

Kumar(JE/HMS),Er. Ravi Gupta(SSE/HMS) who was instrumental in

arranging the vocational training at DLW Varanasi, and without whose

help and guidance the training could not have materialize.

I express my deep sense of gratitude to Mr. S.P.Singh (Principal, TTC)

for given me such a great opportunity.

PREFACE

The objectives of the practical training are to learn something about

industries practically and to be familiar with the working style of a

technical person to adjust simply according to the industrial

environment.

It is rightly said practical life is far away from theoretical one. We

learn in class room can give the practical exposer real life

experience no doubt they help in improving the personality of the

student, but the practical exposure in the field will help the student in

long run of life and will be able to implement the theoretical knowledge.

As a part of academic syllabus of four year degree course in Mechanical

Engineering, every student is required to undergo a practical training.

I am student of third year mechanical and this report is written on

the basis of practical knowledge acquired by me

during the period of practical training taken at Diesel Locomotive

Works, Varanasi.

CONTENTS

[1].Introduction to DLW……………………………………….

[2]. Heavy Welding Shop……………………………………….

[3]. Light Machine Shop………………………………………...

[4]. Truck Machine Shop………………………………………..

[5]. Machine Shop……………………………………………….

[6]. Conclusion…………………………………………………..

[7]. Bibliography…………………………………………………

INTRODUCTION TO DLW

Diesel Locomotive Works (DLW) is a production unit under the ministry of

railways. This was setup in collaboration with American Locomotive

Company (ALCO), USA in 1961 and the first locomotive was rolled out in

1964. This unit produces 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

Microprocessor Controlled AC/AC Freight (GT 46 MAC) / passenger (GT

46 PAC) locomotives and family of 710 engines has been signed with electro

motive division of GENERL MOTORS of USA for manufacture in DLW.

The production of these locomotives has now started and thus DLW is the

only manufacturers of Diesel Electric Locomotives with both ALCO and

General Motors technologies in the world.

Brief History:

Set up in 1961 as a green-field project in technical collaboration with

ALCO/USA to Manufacture Diesel Electric Locomotives.

First locomotive rolled out and dedicated to nation in January, 1964.

Transfer-of-Technology agreement signed with General Motors/ USA in

October, 95 to manufacture state-of-the-art high traction AC-AC diesel

locomotives.

A flagship company of Indian Railways offering complete range of

flanking products in its area of operation.

State-of-the art Design and Manufacturing facility to manufacture more

than 150 locomotives per annum with wide range of related products viz.

components and sub-assemblies.

Unbeatable trail-blazing track record in providing cost-effective, eco-

friendly and reliable solutions to ever-increasing transportation needs for

over three decades.

Fully geared to meet specific transportation needs by putting Price-Value-

Technology equation perfectly right.

A large base of delighted customers among many countries viz. Sri

Lanka, Malaysia, Vietnam, Bangladesh, Tanzania to name a few, bearing

testimony to product leadership in its category.

SALIENT FEATURES:

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 m2

Covered area of other service buildings 73700 m2

Electrical power requirement 3468 KVA

(Average maximum demand)

Electrical energy consumption (units/year) 19.8 million

Standby power generation capacity 3000 KW

PRODUCT OF DLW:

DLW is an integrated plant and its manufacturing facilities are flexible in

nature. These can be utilized for manufacture of different design of locomotives

of various gauges suiting customer requirements and other products. The

product range available is as under:

WDG4 4000 HP AC/AC Freight Traffic Locomotive

WDP4 4000 HPAC/AC Broad Gauge High Speed

Locomotive

WDG3D 3400 HP AC/AC Broad Gauge Mixed Traffic

Micro-Processor Controlled Locomotive.

WDM3C 3300 HP AC/DC Broad Gauge Mixed Traffic

Locomotive.

WDM3A 3100 HP AC/DC Broad Gauge Mixed Traffic

Locomotive.

WDP3A 3100 HP AC/DC Broad Gauge High Speed

Passenger Locomotive.

WDG3A 3100 HP AC/DC Broad Gauge Freight Locomotive.

WDM2 2600 HP AC/DC Broad Gauge Mixed Traffic

Locomotive.

WDP1 2300 HP AC/DC Broad Gauge Intercity Express

Locomotive.

WDM7 2150 HP DC/DC Broad Gauge Mixed Traffic

Locomotive.

WDM6 1350 HP DC/DC Broad Gauge Mixed Traffic

Locomotive.

YDM4 1350 HP AC/DC & DC/DC Broad Gauge Mixed

traffic Locomotive.

EXPORT LOCO 2300 HP AC/DC Meter Gauge/Cape gauge Mixed

Traffic Locomotive.

Diesel Generating Sets 800 KW to 2500 KW

Spare Parts for engines, locomotives and generating sets.

DESIGN OFFICE:

Prepare diag. of each part and sent to Material Control & inform timely in any

change in any parts to relative department.

3D MODEL OF DIESEL LOCO MOTIVE

MATERIAL CONTROL OFFICE:

Prepared material list (ml) which consists diag. & qty. of each part and sent to

store departments for purchase.

FORK LIFT TRUCK

STORE DEPARTMENT:

After receiving of ML, Store Departments scrutiny the ML, take Funds &

vetting from Account department & then issue tenders, Open Tenders &

Purchase Order issued. After Receiving of Material inspection has done by

Inspection Department.

INSPECTION DEPARTMENT:

After Receiving of Material inspection has done by Inspection Deptt. If material

is OK then Receipt Note issued by Store Deptt and sent to Acct. Department for

payment to firm. If material is not OK Then inform to firm to collect the

rejected material.

ACCOUNT DEPARTMENT:

Check all the purchase, given concurrence for purchase, vett the

ML/Requisition & payment to firms.

PLANNING OFFICE:

Prepare JPO, Monthly Production Program, Scheduling, Processing, Rate

Fixing, Issue Work Orders, Schedule Orders, Issue Job card & other production

Documents. Preparing DLW Budget & Sent to Rly Board.

PROGRESS OFFICE:

After opening of work orders collect the prod. Documents from PCO and hand

over to user shop draw the material from depot & given to shop & hand over the

ready material of shop to user shop/store. After completion of work, close the

work order.

PRODUCTION SHOPS:

Production shops are divided in three divisions-

1. Block Divisions

2. Engine Divisions

3. Loco Divisions

BLOCK DIVISION:

1. Heavy Weld Shop

2. Heavy Machine Shop

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

LOCO DIVISION:

1. Loco Frame Shop

2. Pipe Shop

3. Truck Machine Shop

4. Traction Assembly Shop

5.Sheet Metal Shop

6. Loco Assembly Shop

7. Loco Paint Shop

8. Loco Test Shop

SERVICE SHOPS:

1. Maintenance Areas#1, 2, 3

2. Tool Room

3. Central Transport Shop

PERSONNAL DEPARTMENT:

Prepare payment of Staff, Leave Record, Personal Record of every employee,

Housing allotment, welfare of staff etc.

HEALTH DEPARTMENT:

Having facility of Indoor & Outdoor patients.

CIVIL DEPARTMENT:

Maintenance of colony quarters, up gradation of facilities in quarters, sanitation

etc.

ELECTRICAL DEPARTMENT:

Maintenance of Lighting in quarters and in workshop, electrical works in

locomotive etc.

TECHNICAL TRANING CENTER:

Provide training to all employees at time to time to refresh update their

knowledge.

RESEARCH &DEVELOPMENT:

1. R & D - a Customer centric Activity Committed to Innovation and

Continuous Improvement;

2. Highly skilled Manpower capable of handling complete R&D activities;

3. A sophisticated design center with modern CAD/ CAE workstations

equipped with Unigraphics and Ansys;

4. Back-up support from RDSO, a centralized R&D organization at

corporate level;

5. Several milestones in the past - an enviable pedigree viz.

a. original ALCO design made 7% more fuel efficient;

b. many design improvements leading to better performance,

incorporated in the original ALCO design;

c. many new designs for locomotives such as WDP1, WDG2, WDP2

to name a few;

RECENT MILESTONES & FUTURE PLAN:

MILESTONES ACHIEVED:Transfer of technology (TOT) -- An

added feather in the cap:-

Agreement with General Motors of USA for technology transfer to

manufacture high horse-power GT46MAC 4000HP AC/AC locomotive in

India;

Only country outside North-America to have this bleeding edge technology

Many export/repeat orders complied successfully in recent past and many

more in the pipeline; Supplied more than 400 locomotives to various non-

railway customers; Emerging as a leading manufacturer of ALCO/ GM

locomotives for developing countries.

FUTURE PLANS:

• Assimilation of GM technology to manufacture their latest 710 series of

diesel electric locomotives;

• To emerge as a globally competitive locomotive manufacturer;

• To develop as an export hub for ALCO/ GM locos for Asian market;

• To follow an export led growth strategy through continuous

improvement;

Cost effectiveness and technology/ product up-gradation as a key to retain

global competitiveness by putting price-value-technology equation right.

WDP4, 4000 HP PASSENGER LOCOMOTIVE

General Characteristic

Installed Power

Axle Load

Gauge

Wheel arrangement

Wheel diameter

Height

Width

Overall Length (Over Buffer

Beam)

Weight

Max tractive effort

Maximum speed

Fuel tank capacity

Locomotive Control

4000 HP

19.5 T

1676 mm

A-A-I I-A-A

1092 mm

4201mm

3127 mm

19964 mm

117 T

27 T

160 Kmph

4000 lts

EM 2000 with SIBAS-16 Traction

Control

WDP4-4000 HP GOODS

LOCOMOTIVE TRACTIVE EFFORT & POWER CHART

INTRODUCTION OF HEAVY WELDING SHOP:

In the DLW there are basically three type of welding used in HWS. The

welding quality of DLW is very high quality. After the machining process we

can’t say that this piece is not single piece.

1. Submerged arc welding

2. Manual metal arc welding

3. MIG welding

SUBMERGED ARC WELDING:

In submerged arc welding the welding process will be covered with the flux so

that it will not react with oxygen and nitrogen. Because of the versatility of the

process and the simplicity of its equipment and operation, shielded metal arc

welding is one of the world's most popular welding processes.

It dominates other welding processes in the maintenance and repair industry,

and though flux-cored arc welding is growing in popularity, SMAW continues

to be used extensively in the construction of steel structures and in industrial

fabrication. The process is used primarily to weld ironand steels (including

stainless steel) but aluminium, nickel and copperalloys can also be welded with

this method.

GMAW COMPONENTS:

1. DC or Direct Current power supply

2. Electrode or wire feed controller

3. Wire drive roller assembly

4. Shielding gas source (cylinder) & regulator

5. Manually held Gun & ground clamps

6. Wire reel

MIG WELDING:

MIG welding can be used for most types of metals; steel, stainless steel, as well

as aluminium. But welding aluminium is very different from welding mild steel

because aluminium is a metal that is different from steel. So when we weld

aluminium, we have to use other parameters, other settings. Aluminium has a

lower melting temperature than mild steel, for example, so you should expect

that we should use a lower heat input but in spite of this. So we have to use a

higher local heat-input but a faster welding speed than with steel to get good

fusion and penetration. This sounds as if aluminium welding is difficult, but it's

not. The welding sets that we use adjust the welding parameters automatically,

so the welder can concentrate on the welding operation, the movement of the

welding gun and the weld pool.

Dip (short arc) transfer Arc voltage: 15 - 22V Current: >175A Wire stick out: 5 - 12 mm Metals: steel and steel alloys Connection: dc electrode positive Contact tube: 5 mm in front of nozzle tip

Spray transfer Arc voltage: 27 - 54V Current: < 200A Wire stick out: 15 - 20 mm Metals: aluminium (other metals in flat position) Connection: dc electrode positive Contact tube: 5 mm inside nozzle tip

INTRODUCTION TO LIGHT MACHINE SHOP

This shop deals with the matching of various small components required

for the power pack unit such as, cam shaft, connecting rod, liners,

gears,levers, F.P. Support, Piston pin, nuts and bolts bushes, various

shafts etc.

The light machine shop divided into the following section:-

1.Econometric Section

2.Grinding section

3.Gear section

4.Cam shaft section

5.A.T.L. section

6.Belching section

7.Connecting rod section

8.Lathe section

9.Liners section

10.Drilling section

11.Milling section

01. Econometric section:This section manufacturing various sizes etc.

Machine provided: - econometric machine, do-all machine, belt grinding

machine (for control shaft feed)

02. Gear- Section:

This section deals to making various gears impeller such as: cam shaft gear,

crank shaft gear, extension shaft gear, impeller gear (follower & drive) and

broaching Machine Provided:-

(a) gear hobbling machine

(b) gear shaving machine

(c) V.T.L. machine

(d) Radial drilling machine

(e) Broaching machine

(f) Centre mill M/C

03. Grinding Section:

In this section the various small components are grinding as per required

finishing after machining operation and each components having grinding

allowance (G.A.) main piston pin, impeller and fuller and follower gear,

pin valve guide, various studs. Cam roller, seat (V/C Q ‘X’ head) spider

various bushes etc.

Machine provided:

a. cylindrical grinding machine

b. internal grinding machine

c. Centre less grinding machine

d. thread rolling machine

e. universal grinding machine

f. external grinding machine

04. Camshaft section:

This section making cam shaft (both B.G. & M.G.) with completed

machining operation by various special type of machine. In B.G. 08 no’s

per loco and in M.G. 03 per loco.

Machine Provided:

1. Centre mill machine

2. Auto lathe machine

3. Gun drill machine

4. External grinding machine

5. Lathe machine

6. Cam grinding machine

7. Radial drilling machine

8. Cam angle checking machine

9. Magna flux machine

05.Automatic Turret Lathe (A.T.L) Section:

This section manufacturing various types of small components for Power

pack engine such as:

Lock spring seat (V/L & X-Hd) spewing seat. Ball end, cup end ad.

Screw (X-HD & V/L) cop screws L.A.S. retainer, spring lever, F.P. inlet,

Porg Bkt. piston pin liner sleeve, body outer ring spicier etc.

Machine Provided:

1. M.T.L. ( Bar type , chuck type)

2. U.T.L.

The A.T.L. section is the vital section of this shop. Maximum small

components are manufacturing in the section.

06. Benching Section:

In this section the benching operation of the entire component which are

manufacturing in the shop are done here. In the benching section, there

hawing hand cutter machining and belt grinding machine, with the half of

these machine bar removing from all the components.

07. Connecting rod section:

In this section the connecting rod is made. All the machining operations

of the connecting rod, completed here with the help of various types of

machine. The connecting rod has two parts, one is cap and other is rod.

The material of the connecting rod is steep forging. In B.G. 16 per loco

and in M.G. 6 per loco.

Main dimensions:

1. crank bore (big bore) =6-411” to 6.421”

2. piston pin bore (small bore)=3.998” to 3.999”

3. Distance Between Two = 20.995” to 21.000” bare Centre

4. Rod Thickness = 3.020” to 3.022”

5. Weight = 32 Kg 950 gram to 32 Kg gram.

6. Pressure Torque = 150 P.S.I.

08. Lathe section:

This section deals various types tropical small components are

manufacturing. Centre lath machines oar provided in this section.

The components are: brass sleeve, wear plate, valve guide, long stud,

shaft etc.

In drum type turret lathe M/C manufacturing pin cam roller, cup end,

bush washer etc.

09. Cylinder Liner Section:

In this section .cycle liner machine operation have done here by the

various type of m/cs. the material of the cylinder Liner is special Cast

iron and the set the per loco is in B.G. 16 and in M.G. 6 cylinder.

Main Dimension:-

1. Length 21 15/16 + 1/64

2. Inside dia. rough honing -9.010”

3. Inside dia. finish honing – 9.015”

4. outside dia. – 10.00”

5. Dia. of groove – 10.749 to 10.750”

Machine provided:-

1. Shot blast machine.

2. Vertical boring machine

3. Auto lathe machine.

4. Honing machine.

5. Cylindrical grinding machine.

10. Drilling Section :

In this section dials with various Types of drilling, reaming, counter

bore spot tracing and counter sinking operation done of various small

components.

The components are, F.P. support, P.R. Lighter, X head, Valve Lever,

Spring Lever, Brg, Bracket, Pin, Ecc Lever, Upper housing etc.

Machine Provided:-

1. Radial drilling Machine,

2. Gang drilling machine of multy spindle drilling machine

3. Drilling Machine

4. Electronic drilling machine.

11. Milling Machine:-

This section manufacturing various types of milling operation of the

components in different types of milling machine-

Machine Provided:-

1. Vertical milling machine

2. Horizontal milling machine

3. Universal milling machine.

INTRODUCTION TO MACHIN SHOP

Machine shop work is generally understood to include all cold-metal work by

which an operator, using either power driven equipment or hand tools, removes

a portion of the metal and shapes it to some specified form or size. It does not

include sheet metal work and coppersmithing. The function of all machine tools

is to produce metal parts by changing the shape, size, or finish of a piece of

material. The shape of a part made with a machine tool is limited by the types of

motion the tool can apply.

Standard machine tools are grouped in six basic classes:

1. LATHES

2. DRILLING MACHINES

3. SHAPERS

4. PLANERS

5. MILLING MACHINES

6. GRINDING MACHINES

LATHE:

The lathe is used for turning various metals against a cutting tool that shapes it

to the desired product. The engine lathe is a machine tool that produces a

cutting action by rotating the work piece against the cutting edge of the tool.

DRILLING MACHINES: The drilling machine is a machine tool that produces the necessary cutting

action by the rotation of a multiple edge cutting tool.

SHAPING AND PLANING MACHINES: Both of these machines can machine flat surfaces with a single point

reciprocating, motion is applied to both the work piece and tool in these

machines.

MILLING MACHINES: A milling machine provides cutting action to a rotating tool. The vertical

milling machine is used to cut, shape, and finish metal objects.

GRINDING MACHINES A grinder differs from other machines in that it uses a tool made of emery,

Carborundum, or similar materials. The wheel, made up of many tiny cutting

points, cuts with the entire surface area that comes in contact with the material

being ground. Grinders cut with a grinding action, removing material in the

form of tiny particles.

SAFETY RULES FOR MACHINE TOOLS:

The following are general safety rules for any machine tool:

1. Gears, pulleys, belts, couplings, ends of shafts having keyways, and other

revolving or reciprocating parts should be guarded to a height of 6 feet

above the floor. The guards should be removed only for repairing or

adjusting the machine and must be replaced before operating it.

2. Safety setscrews should be used in collars and on all revolving or

reciprocating members of the machine tool or its equipment.

3. Do not operate any machine tool without proper lighting.

4. Never attempt to operate any machine tool until you fully understand how

it works and know how to stop it quickly.

5. Never wear loose or torn clothing and secure long hair, since these items

can become caught in revolving machine parts. Ties should be removed

and shirt sleeves should be rolled up above the elbow.

6. Gloves should never be worn when operating machinery except when

absolutely necessary.

7. Always stop the machine before cleaning it or taking measurements of the

work piece.

8. Do not lubricate a machine while it is in motion. Injury to the operator and

damage to the machine may result from this practice.

9. Always wear safety glasses or goggles while operating machine tools.

Also, wear respiratory protection if operation creates hazardous dust. All

persons in the area where power tools are being operated should also wear

safety eye protection and respirators as needed.

10. Know where tire extinguishers are located in the shop area and how to use

them.

11. Never wear jewellery while working around machine tools. Rings,

watches, or bracelets maybe caught in a revolving part which could result

in the hand being pulled into the machine.

12. Avoid horseplay. Tools are very sharp and machines are made of hard

steel. An accidental slip or fall may cause a serious injury.

13. Never use compressed air without a safety nozzle to clean machines or

clothing. It will blow sharp, dangerous metal chips a long distance.

14. Never place tools or other materials on the machine table. Cluttering up a

machine with tools or materials creates unsafe working conditions. Use a

bench or table near the machine for this purpose.

15. Always use a rag when handling sharp cutters such as milling cutters and

end mills.

INTRODUCTION TO TRUCK MACHINE SHOP:

The shop deals with the matching various small component such as pinion,

Axial wheel, collar, gearing, gear etc.

(1). Truck frame machining section

(2). Center lathe machine section

(3). U.T.L section

(4). Axial wheel machine section

(5). Miscellaneous machine section

(6).Axial wheel and box assembly section

(7). Truck frame sub assembly section

(8). Truck frame fabrication section

(9).Truck frame assembly section

CONCLUSION

RECENT MILESTONES & FUTURE PLAN:

MILESTONES ACHIEVED:

Transfer of Technology (TOT):

An added feather in the cap:-

1. Agreement with General Motors of USA for technology transfer to

manufacture high horse-power GT46MAC 4000HP AC/AC locomotive in

India;

2. Only country outside North-America to have this bleeding edge technology;

3. Many export/repeat orders complied successfully in recent past and many

more in the pipeline;

4. supplied more than 400 locomotives to various non-railway customers;

5. Emerging as a leading manufacturer of ALCO/ GM locomotives for

developing countries.

FUTURE PLANS:

1. GM technology to manufacture their latest 710 series of diesel electric

locomotives;

2. To emerge as a globally competitive locomotive manufacturer;

3. To develop as an export hub for ALCO/ GM locos for Asian market;

4. To follow an export led growth strategy through continuous improvement

5. Cost effectiveness and technology/ product up-gradation as a key to retain

global competitiveness by putting price-value-technology equation right.

BIBLIOGRAPHY

1. www.indianrailways.gov.in

2. Cris-dlw.cirs.org.in

3. www.irfca.org