DIESLE LOCOMOTIVE WORK (DLW)VARANASI, UTTERPRADESH

A TECHNICAL SEMINAR

BACHELOR OF TECHNOLOGY(Mechanical Engineering)

SUBMITTED TOAMC ENGINEERING COLLEGE ,

BANGALORE

SUBMITTED BY University Reg.no

VIPIN KUMAR RAI 1AM12ME103

AMC ENGINEERING COLLEGE, BANGALOREKARNATAKA

Diesel Locomotive Works Varanasi, (Uttar Pradesh)

A TRAINING REPORT

TABLE OF CONTENTS

Training Certificate Acknowledgement Preface Introduction to D.L.W Welding Lab TTC Rotor Shop Loco Painting Shop Machining Lab TTC Sub Assembly Shop Tool Room Demerit

ACKNOWLEDGEMENT

I would like to thank “DLW Technical Training Centre (TTC), Varanasi” for the solemnly support to the students for their Industrial training program.

I express my sincere gratitude to Mr. _________________________, Principal of Technical Training Centre for the support and encouragement he provided.

I also wish to extend my thanks to the Respected Engineers, Junior Engineers and the Workers of different sections and sub-sections of DLW who provided us the knowledge about the different machining processes, Assembling process and their workings.

I am extremely thankful to prof._________________, HOD, Amc engineering college , Bangalore, for his valuable suggestions and encouragement.

I am also thankful to Mr.________________, Training and placement officer, AMC, Bangalore for providing the opportunity to us by which we can get some industrial knowledge.

Signature of studentVipin kumar rai (1am12me103)

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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.

INTRODUCTION TO D.L.W

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 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 later, on January 3, 1964. It manufactures locomotives.

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 up to 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 PSU’s & Industries like NTPC, COAL, and INDOGULF etc.

DLW Varanasi is further divided into sections and sub-sections from where the job get completed.A flagship production unit of Indian Railways offering complete range of products in its area of operation with annual turnover of over 2124 Crore. State of the art Design and Manufacturing facility to manufacture 200 locomotives per annum with wide range of related products viz. DG Sets, Loco components and sub-assemblies. Supply of spares required to maintain Diesel Locomotives and DG sets.

DLW VISION:"To be a world class manufacturer of reliable, cost-effective, state of the art Diesel - electric locomotives." 

DLW MISSION:We shall achieve our vision through 

♦ Focus on quality for sustained and continuous improvement in reliability & performance on the product leading to customer satisfaction. 

♦ Developing core competence with due emphasis on innovation, human resource development and team work. 

♦ Achieving environmental excellence by prevention of pollution, reduction of emissions, energy conservation and preservation of natural resources. 

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DLW PRODUCTION WORKSHOP FLOWCHART

PRO

DUCT

ION

SHO

PSBLOCK DIVISION

ENGINE DIVISION

LOCO DVISION

BLOCK DIVISION

HEAVY WELD SHOP

HEAVY MACHINE

SHOP

2

ENGINE DIVISION

LIGHT MACHINE SHOP

SUB ASSEMBLY SHOP ROTOR SHOP HEAT TREATMENT

SHOP

ENGINE ERECTION SHOP

ENGINE TESTING SHOP

LOCO DIVISION

LOCO TEST SHOP

LOCO FRAME SHOP

PIPE SHOP

TRUCK MACHINE

SHOPTRACTION ASSEMBLY

SHOP

SHEET METAL SHOP

LOCO ASEEMBLY

SHOP

LOCO PAINT SHOP

3

SOME BASIC FACT ABOUT DIESEL ELECTRIC LOCOMOTIVE

DLW’s annual production - 250

Cost of one loco - 12 to 14 crore (EMD)

8 crore (Alco)

Weight of one Loco - 121 Ton

Fuel Consumption; At Full Load - 540 ltr /hr.

Idle Load - 40 ltr/hr.

Max. Speed - 160 Km/hr.

Diameter of Wheel - 1092 mm

Wheel to Wheel Distance - 1596.5 mm

Length of Under Frame - 19962 mm

TYPES OF LOCOMOTIVES PRODUCED

Following types of diesel loco are being produced in the DLW:

1. WDM - Wide Diesel Mixed

2. WDP - Wide Diesel Passenger

3. WDG - Wide Diesel Goods

4. WDS - Wide Diesel Saunter

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WIDE DIESEL MIXED (WDM)

Specification of WDM class

Power type Diesel

Builder Alco, DLW

Model DL560C

Build date 1962 onwards

5

Total production 2700+

Gauge 1,676 mm (5 ft 6 in)

Wheel diameter 1,092 mm (3 ft 7.0 in)

Wheelbase 12.834 m (42 ft 1.3 in)

Length 17.12 m (56 ft 2 in)

Width 2.864 m (9 ft 4.8 in)

Height 4.185 m (13 ft 8.8 in)

Axle load 18,800 kg (41,000 lb)

Locomotive weight 112,800 kg (249,000 lb)

Fuel capacity 5,000 ltr (1,100 imp gal;

1,300 US gal)

Prime mover ALCO 251-B

Engine RPM range 400 - 1000 rpm

Aspiration Turbo-supercharged

Cylinders 16

6

Top speed 120 km/hr (75 mph)

Power output 2,400 hp (1,800 kW)

The class WDM-2 is Indian Railways' workhorse diesel locomotive. The first units were imported fully built from the American Locomotive Company (Alco) in 1962. Since 1964, it has been manufactured in India by the Diesel Locomotive Works (DLW), Varanasi. The model name stands for broad gauge (W), diesel (D), mixed traffic (M) engine. The WDM-2 is the most common diesel locomotive of Indian Railways.

The WDM-2A is a variant of the original WDM-2. These units have been retro-fitted with air brakes, in addition to the original vacuum brakes. TheWDM-2B is a more recent locomotive, built with air brakes as original equipment. The WDM-2 locos have a maximum speed of 120 km/h (75 mph), restricted to 100 km/h (62 mph) when run long hood forward - the gear ratio is 65:18.

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WIDE DIESEL GOOD (WDG)

Builder EMD & DLW

Model GT46PAC

8

Build date Power type

Total production (EMD) 10; (DLW) 80+

under license (in production)

Gauge 5 ft 6 in (1.68 m)

Trucks HTSC

Fuel type Diesel

Fuel capacity 6,000 liters

Prime mover 16-710G3B

Engine type 2-stroke diesel

Aspiration Turbocharged

Displacement 11,360 in² (186.2 liters)

Alternator TA-17-CA6A

Traction motors AC

Cylinders V16

Transmission electric; AC alternator, 1 inverter

per truck, AC traction motors

Power output 9

• 4,000 hp (WDP-4)

4500 hp (WDP-4B and WDP-4D)

Locomotive brakes Air

Train brakes Air

The WDP-4 is capable of hauling 24 coach trains at 110-120 km/hour. It has also been used for speed trials where it has hauled 8 coach trains at 160 km/hour.

NOMENCLATURE OF LOCOMOTIVES

The first letter (gauge)

1. W-Indian broad gauge (The "W" Stands for Wide Gauge - 5 Feet)

2. Y-meter gauge (The "Y" stands for Yard Gauge - 3 Feet)

3. Z-narrow gauge(2 ft. 6 in)

4. N-narrow gauge (2 ft.)

The second letter (motive power)

1. D-Diesel

2. C-DC electric (can run under DC traction only)

3. A-AC electric (can run under AC traction only)

4. CA-Both DC and AC (can run under both AC and DC tractions), 'CA' is considered a single letter

5. B-Battery electric locomotive (rare)

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The third letter (job type)

1. G-goods

2. P-passenger

3. M-mixed; both goods and passenger

4. S-Used for shunting (Also known as switching engines or switchers in United states and some other countries)

5. U-Electric multiple units (used as commuters in city suburbs)

6. R-Railcars

For example, in "WDM 3A":

1. "W" means broad gauge

2. "D" means diesel motive power

3. "M" means suitable for mixed(for both goods and passenger)service

4. "3A" means the locomotive's power is 3,100 hp ('3' stands for 3000 hp, 'A' denotes 100 hp more)

Or, in "WAP 5":

1. "W" means broad gauge

2. "A" mean AC electric traction motive power

3. "P" means suitable for Passenger service

4. "5" denotes that this locomotive is chronologically the fifth electric locomotive model used by the railways for passenger service

PROBLEM WHICH IS FACED BY INDIAN RAILWAY ENGINE

Old track and poor state of rolling stock

Travel without tickets Railway accident

Attack on railway

Lack of modern management