1 1.

Organization Overview

1.1.Type of organization: Diesel Locomotive Works (DLW) established in 30 April 1956. Diesel Locomotive Works (DLW) got its first ISO certification in 1997, recently DLW has obtained the integrated Quality and environment management system certification based on ISO9001 and ISO14001 in December 2002.DLW is proud to be the pioneer in this area amongst the government/public sector units in the country. Diesel Locomotive Works (DLW) is the organization of Indian railways. Diesel Locomotive Works (DLW) is the organization which makes the diesel electric rail engine for the Indian railway. Diesel Locomotives Works (DLW) is making two types of diesel electric rail engine for the Indian railways. These two types of rail engines are ALCO and EMD diesel rail engine. Diesel Locomotive Works (DLW) also makes DG Set for the Indian railways.

1.2.Manufacturing: Diesel Locomotive Works (DLW) manufactures the diesel electric locomotive engine for Indian railways. Diesel Locomotive Works (DLW) manufactures two types of diesel electric locomotive engine. First one is ALCO type of diesel electric engine. It is 4 stroke engines so it is produces less power. Thats why this type of diesel engine has less production. Second type of diesel engine is EMD engine. It is 2 stroke engines. So it is produces more power so it is also known as High Horse Power (HHP) or General Motor (GM).

1.3.Location: Diesel Locomotive Works (DLW) is located in the Indias holy city Varanasi (Uttar Pradesh). In the Varanasi Diesel Locomotive Works (DLW) place around 300 hectares. This Diesel Locomotive Works (DLW) helps in the progress of the Indian railways and India.

2 1.4. Specialization of Work Culture in the Diesel Locomotive Works (DLW): In the Diesel Locomotive Works (DLW) they are following specialization of work culture: 1.4.1. Flame Cutting of Components: Steel plates of sizes up to 80 mm thickness are ultrasonically tested before being precision cut by numerically controlled flame cutting machines, Plasma Cutting Machine.

Components are straightened and machined prior to fitting & tacking on fixture designed especially for engine block fabrication to ensure close tolerance on engine block. 1.4.2. Fabrication of Engine Block/ Crankcase: Components after flame cutting and various machining operations are fit and tack welded before taking on rollovers. Heavy Argon-CO2 welding is done on these rollovers. High quality of welding is done by qualified welders. Weld joints are subjected to various tests like ultrasonic, X-rays, Visual etc.

Down-hand welding is ensured using specially designed positioners. Fabrication of engine block is completed by submerged arc welding using semiautomatic welding machines. 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.

After complete welding weldment is stress relieved and marking is done for subsequent machining. 1.4.3. Portal Milling Machine: Engine block machining is done on Portal Milling Machine which is a 5 axis CNC machine with SIEMENs 840-D state of art system control with dedicated tool management system. This machine performs milling, drilling, tapping and boring operations in single setting. The machine accuracy of 10enables adhering to the tolerance required on engine block.

4 1.4.4. Angular Boring Machine: Angular boring "V" boring is done of special purpose machine which is a special purpose machine, which has two high precision angular boring bars on which different boring inserts are mounted.

The cutting inserts on boring bars to achieve evenly distributed cutting load during boring operation. This contributes to accuracy while machining. Boring bars are mounted on high precision bearings which provide control on size during angular boring. The machine is capable of boring and drilling to different sizes.

1.4.5. Component machine: Over 2000 components are manufactured in-house at DLW. These include ALCO turbo superchargers, lubricating oil pumps, cam shafts, cylinder heads, laser hardened 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.

Associated manufacturing process like heat treatment and induction hardening are also carried out in-house.

A new eco friendly laser hardening machine has been setup which is designed to laser harden the inner bore of engine cylinder liner and this feature advantages such as low running cost, state of the art controls to provide reliable and versatile laser power for ultimate quality requirements.

1.4.6. Engine Assembly & Testing: Pre-inspected engine block, crankshaft, cylinder liners, pistons, connecting rods, cylinder heads, exhaust manifold, turbo supercharger and all related piping are used in assembly of engine. Electrical machines like traction alternator, auxiliary generator and exiter are thereafter coupled on the engine.

The complete power pack with electrics are tested on computerized Engine Test Bed to verify prescribed horsepower output. Vital parameters of engine health are checked to assure the quality of product.

Only after the engine parameters are found perfect the power pack are cleared for application on locomotives.

1.4.7. Component Fabrication: Precision cutting and forming of sheet metal is utilised 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.

All electrical equipment is assembled in the fabricated control compartments and driver's control stands are done in another work area.

8 1.4.8. Under frame Fabrication: Under frames are fabricated with due care to ensure designed weld strength. Requisite camber to the under frame is provided during fabrication itself. Critical welds are tested radio-graphically.

Welder training and their technical competence are periodically reviewed. High Horse Power (HHP) under frame is fabricated using heavy fixtures, positioners to ensure down hand welding. Fixtures are used to ensure proper fitting of components and quality welding in subsequent stages.

9 1.4.9. Bogie Manufacturing: Special purpose machines are utilized for machining cast and fabricated bogie frames. Axle and wheel disc machining is undertaken on sophisticated CNC machines. Inner diameter of wheel discs are matched with the outer diameter of axles and assembled on wheel press. The complete truck (bogie), including bogie frames, wheels and axles, brake rigging and traction motors are assembled which is ready for application to locomotive.

1.4.10. Loco Assembly: Tested engines are receives from Engine Division. Similarly under frames are received from Loco frame shop and assembled trucks from Truck machine shop. Superstructure compartments and contractor compartment 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.

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. All locomotive are rigorous tested as per laid down test procedures before the locomotive is taken up for final painting and dispatch for service. 1.5 About the External Guide:

10 In diesel locomotive works (DLW) there are Section Engineer (SE) who guides by the taking lecture in the lecture hall and give the knowledge about the cylinder block machining, EMD engine, Engine testing, Under frame manufacturing process, Bogie, Loco assembly, Loco Testing method, different type of locomotive and there nomenclature etc. Mr. Ravi Gupta sir who is section engineer in the HWS told about the cylinder block machining and there operations. Mr. Sanjay Kumar sir who is section engineer in the Engine shop told about EMD engine and its firing order. Mr. Ajay Verma sir who is section engineer in the Engine Testing Shop (ETS) told about engine testing. Mr. A.K Shrivastav who is section engineer in Loco Frame Shop (LFS) told about the under frame manufacturing process. Mr. Ashok Kumar Kharwar who is junior engineer in Light Machine Shop (LMS) helped during the summer vocational training. Many workers also helped during the vocational training and told many things. 2 Technology Learnt

In Diesel Locomotive Works (DLW) there are many Workshops for learning and visiting. These workshops are HWS, HMS, EES, ETS, LMS, LAS, SAS, RS, HTS, LFS, PS, TMS, TAS, SMS, LAS, LPS, and LTS etc. These are the workshops in the Diesel Locomotive Works (DLW) where student get knowledge about practical experience. There are some workshops in TTC (Technical Training Center) like Fitting shop, Machine Shop and Welding Shop. In Diesel Locomotive Works (DLW) I have visited 6 Works shop in six week. These works shop are Fitting shop, Machine shop, HWS (Heavy Welding Shop), LAS (Loco Assembly Shop), RS (Rotor Shop) and TMS (Truck Machine Shop).

2.1 Fitting Shop

11 First week I have visited fitting shop. This is inside the TTC (Technical Training Center). In the fitting shop workers of diesel locomotive works (DLW) learn about the fitting. In the fitting shop I have visited many things Fitting tools: The tools use in fitting shop is classified into following groups. Measuring tools: These tools are use to measure the length, Diameter and height. These measuring tools are Steel Rule, Inside Caliper, Outside Caliper, Vernier Caliper and Micro meter. Holding device: These device is use to hold the job. In have seen Parallel Jaw Vice is use to hold the job in fitting shop. Cutting tools: These tools are use for cutting the job. I have seen these cutting tools in DLW fitting shop Hacksaw, chisel and files Striking tools: These tools are use to strike the job. These type of tool are hammer. I have seen these hammers in DLW fitting shop Ball peen hammer, straight peen hammer, cross peen hammer. Marking tools: These tools are use for marking the job. I have seen in DLW fitting shop theses marking tool Scriber, Divider and Center Punch.

2.2 Machine Shop

12 Second week I have seen machine in diesel locomotive works (DLW). Machine shop is inside the Technical Training Center (TTC). Where workers and student are learns basic thing about the machine which is use to make diesel locomotive works (DLW). I have seen following machine in the machine shop Lathe Machine: The lathe is used for producing cylindrical work. The work piece is rotated while the cutting tool movement is controlled by the machine. Shaper Machine: Shaper is a machine used for the production of flat surfaces in vertical, horizontal, or angular planes. Drilling Machine: A machine designed to hold drill bits which will produce cylindrical holes. Milling Machine: A milling machine uses a rotating tool to produce flat surfaces. A very flexible, light-duty machine. Grinding Machine: Grinding is a cutting technique used when close tolerances and very smooth finishes are required. CNC Machine: The automation of machine tools that are operated by abstractly programmed commands encoded on a storage medium, as opposed to controlled manually via hand wheels or levers, or mechanically automated via cams alone. These are CNC operation contour milling, face milling, slot and keyway cutting, template drilling, reaming, and boring.

Operation: Following operation I have seen in DLW

13 1. Turning operation: In this operation shaft is make circular and cylindrical. This is done on center lathe 2. Facing operation: Facing is a lathe operation in which the cutting tool removes metal from the end of the work piece. 3. Boring: Boring is an operation to enlarge and finish holes accurately. This may be done on a lathe or a milling machine. 4. Drilling operation: Drilling is an economical way of removing large amounts of metal to create semi-precision round hole or cavity. 5. Grinding operation: Grinding is an operation in which the cutting is done by the use of abrasive particles. 6. Shaping: Shaping is an operation used to produce flat surfaces.

2.3 Loco Assembly Shop (LAS) Fourth week I have seen LAS (Loco Assembly Shop). In LAS I have seen there are step by step process for the assembled the locomotive. There is a sequence for assemble. In LAS Electrical control equipment is fitted and control cable harnessing is undertaken. The complete locomotive is thus assembled before being sent onwards for final testing and spray painting. Tested engines are received from Engine Division. Similarly under frames are received from Loco frame shop and assembled trucks from Truck machine shop. Superstructure compartments and contractor compartment 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.

Operation in LAS:

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1. Drive cap assembly Air compressor assembly Control stand assembly 2. Driver cap checking Air brake piping 3. Long hood assembly Buffer assembly Radiator setting 4. Engine setting Compressor setting 5. Long hood setting Auxiliary generator assembly and setting Alternator part packing and assembly 6. Equipment assembly Fuel oil parking Lube oil piping Engine water cooling piping 7. Driver sheet setting Damper assembly Air duct setting

2.4 Heavy Welding Shop (HWS)

15 Third week I have heavy welding shop (HWS). Heavy welding shop (HWS) is inside the shop floor. There is all shop of manufacturing process. In heavy welding shop (HWS) there are made 16 cylinder V block engine. This engine is made by fabrication. I have seen following things in HWS. Different welding proses in HWS: Flame Cutting of Components: I have seen flame cutting in the HWS. Steel plates of sizes up to 80 mm thickness are ultrasonically tested before being precision cut by numerically controlled flame cutting machines, Plasma Cutting Machine.

Gas Welding: In gas welding I have seen Gas Metal Arc Welding (GMAW). In gas metal arc welding they use inert gas for resist corrosion effect and wire of mild steel (MS).

Submerged Arc Welding: In HWS I have seen submerged Arc Welding. In submerged Arc Welding Lincoln Electric Flux is used. This flux is used to resist the corrosion effect.

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Fabrication of V Block engine: all they take saddle. Saddle used in the ALCO engine. Saddle has three types.

1. Saddle: Saddle is a base on which other sheets are joined by fabrication. First of Intermediate saddle: 7 intermediate saddles is use in ALCO engine. It width is 4.5. Centre saddle: 1 centre saddle is use in ALCO engine. It width is 6.75. T saddle: 1 T saddle is use in ALCO engine. It width is 4.625.

Total number of saddle used is 9 in ALCO engine. 2. Second operation is joined the foundation plate at saddle. 2 foundation plates are joined at saddle. One is left side and other is right side. 3. Third operation is spline Joined at saddle. 1 spline is joined at saddle. 4. Fourth operation is joined outside wall. 2 outside wall are joined. One is left side and other is right side.

17 5. This operation is joined 2 middle deck centre. One is left side and other is right side. It width is 40 mm. 6. This operation is joined 2 in side wall. One is left side and other is right side. It width is 20 mm. 7. This operation is joined 2 top Deck. One is left side and other is right side. 8. This operation is making water comportment. 9. This operation is joined side sheet. 10. This operation is joined end plate. 11. This operation is making fuel self. 12. This operation is joined top deck centre.

2.5 Rotor Shop (RS) Fifth week I have seen Rotor Shop (RS). 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

18 2. Inducer 3. Nose piece 4. Stud Rotor 5. Nut 6. Washer 7. Thrust Washer 8. Key 9. Oil Slinger 10. Turbine Disc 11. Turbo Shaft 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. 3. Casing:--

19 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.

Working of Turbocharger:-Exhaust gasses are entering form inlet strikes onto the nozzle disc. Then it will strike onto the turbine blade. Due to this the turbine starts rotating at a speed from 018000rpm. It will be transfer the motion to compressor which is comprises with impeller & inducer. From that rotation sucking of fresh air from environment is occurring. That air is now entered in intermediate casing and blow from blower casing. SALIENT FEATURE OF G.M. MOTOR TURBOCHARGER 1. No. per engine1 2. StagesSingle stage 3. DriveMechanical drive as well as exhaust gas driven with ver running clutch. 4. Air Flow6.35kg/s (Rated O/P) 5. Efficiency (At match pt.)- Turbine87.2%

20 compressor81.5% Mechanical87.8% Compressor Stage --Air temperature up to 190.6C Turbine stage---Gas temperature up to 593.3C --Gas temperature up to 482.2C on outlet side. 7. Pressure Ratio of Compressor 2.8 8. Temp. (Charge air after compressor)-- 171C 9. Speed of Turbo (At rated O/P)18,950rpm

6. Temperature for which critical components are designed

2.6

Truck Machine Shop (TMS)

Sixth week I have seen Truck Machine Shop (TMS). In this shop they make wheel, axle. After making axle and wheel they assemble the axle and wheel. In TMS the assembled wheel, axle, bull gear, bearing cap of axle etc. Bogie:There are two types of bogie Co-Co bogie Bo-Bo bogie

1. Co-Co bogie: Co-Co bogie has three axles and six wheels. 2. Bo-Bo bogie: Bo-Bo bogie has two axles and four wheels. Manufacturing of bogie: There are two of manufactured bogies 1. 2. Fabricated bogie Casting bogie

1. Fabricated bogie: In fabricated bogie, bogie made by the cutting and welding. In DLW fabricated bogie uses mostly. 2. Casting bogie: In the casting bogie, bogie is manufactured by casting.

21 Important parts of bogie: 1. Bogie frame: A bogie is a wheeled wagon or trolley. In mechanics terms, a

bogie is a chassis or framework carrying wheels, attached to a vehicle. Bogie on which super structure and under frame is mounted. It is two type Co-Co and Bo-Bo bogie. Co-Co has three axles and six wheel and Bo-Bo has two axles and four wheel.

2. holes. 3. 4.

Axle: EMD engine axle has three hole but in ALCO engine axle has eight

wheels Bull gear

5. 6.

suspension tube axle boxes

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7. Traction motor: Electric motor providing the primary rotational torque of a machine, usually for conversion into linear motion. DC series-wound motors, running on approximately 600 volts.

8. 9.

brake riggings items air pipe 3. Reason for choosing this training

I choose Diesel Locomotive Works (DLW) for summer vocational training because It is the department of Indian Railways. It is only in India which manufactured Diesel Locomotive. It is ISO-9001, ISO14001 and OHS 18001 certified. DLW high production rate 250 locomotive per year. In Diesel Locomotive Works (DLW) there are many heavy and advance machines like Portal milling machine, Angular boring machine, CNC machine etc.

23 In Diesel Locomotive Works (DLW) there are high and advanced welding technics like Submerged Arc Welding, Forging welding, Gas Metal Arc Welding and etc. Diesel Locomotive Works (DLW) exports their products to other country like Shri Lanka, Angola, Vietnam, Tanzania, Bangladesh & Malaysia. They making Diesel engine of two types EMD and ALCO. One two stroke and other is four stroke. So we can no common difference between them. We can know about diesel engine and its firing orde.

4. Learning Outcome from training:

4.1.Nomenclature of diesel locomotive: The first letter (gauge) 1. W-Indian broad gauge (The "W" Stands for Wide Gauge - 5 Feet) 2. Y-metre 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) D-Diesel C-DC electric (can run under DC traction only)

24 A-AC electric (can run under AC traction only) CA-Both DC and AC (can run under both AC and DC tractions), 'CA' is considered a single letter B-Battery electric locomotive (rare) 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 The forth letter (horse power) For example, in "WDM 3A": "W" means broad gauge "D" means diesel motive power "M" means suitable for mixed(for both goods and passenger)service "3A" means the locomotive's power is 3,100 HP ('3' stands for 3000 HP, 'A' denotes 100 HP more) 4.2.Engine: There are two type of engine EMD (Electro motive Division) ALCO (American Locomotive) The third letter (job type)

EMD is two stroke diesel engines and ALCO is four stroke diesel engines. Turbocharger end is known as turbo or alternator or rear end and governor and accessories is known as accessory or governor or front end. EMD engine is known as HHP (high Horse Power) or GM (general motor). EMD engine has maximum power is 4500 HP and ALCO engine has maximum Power is 3300 HP.

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4.3.Machine used in fabrication: Flame cutting machine Shearing machine Bending machine Drill machine Welding machine Press brake machine

4.4.Cylinder blocks machining: Machine used for cylinder block machining: Planner machine Horizontal milling machine Angular boring machine

In the lecture I know about cylinder blocks machining. After fabrication of cylinder block following operation is doing

Operation5. Making Operation10. Machining, top deck, top dead center and side sheet. Operation15. Machining of Foundation Rail by Planner machine Operation20. Machining of End plate by Horizontal milling machine. Operation25. Drilling, tapping and reaming of different size of hole. Operation30. Boring of cylinder liner by angular boring machine. Operation35. Foundation rail drilling and tapping. Operaton40. Drilling and tapping of top dead center and top deck. Operation45. Drilling and tapping of side sheet. Operation50. Making serration in crank bore. Operation55. Assembly of main bearing cap. Operation60. Crank and cam boring by horizontal boring machine

26 Operation65. Crank bore honing. Operation70. Capping remove. Operation75. Check alignment. 4.5.Flow chart for loco testing:

5. Gantt chart

Shop/Week Lecture + Fitting shop Lecture + Machine shop Loco Assembly

1 Week

2 Week

3 Week

4 Week

5 Week

6 Week

27 Shop(LAS) Heavy Welding Shop(HWS) Rotor shop(RS) Truck Machine Shop(TMS)

6. Bibliography www.dlw.indianrailways.gov.in http://trainweb.org/railworld/DLW/ http://www.scribd.com/doc/64559155/Report-on-Summer-Training-at-DlwVaranasi http://www.scribd.com/doc/54456974/Summer-Traning-DLW-Report http://www.scribd.com/doc/45187594/Summer-Training-Diesel-LocomotiveWorks-Ppt