TRAINING REPORT

On

DIESEL LOCOMOTIVE WORKS

Submitted to Kurukshetra University in partial fulfilment of the for the award of the degree of

B.TECH
in

MECHANICAL ENGINEERING Submitted By RAJ MOHAN RAI Roll. No. 4110640

DEPTT. OF MECHANICAL ENGINEERING

YAMUNA INSTITUTE OF ENGINEERING &TECHNOLOGY GADHOLI, YAMUNANAGAR-133103

PREFACE
Training is an integral part of B.Tech and each and every student has to undergo the training for 4 weeks in a company. This record is concerned about our practical training during the Summer Vacations of 3rd year. We have taken our Practical training in DIESEL LOCOMOTIVE

WORKS,VARANASI(U.P) During this training, we got to learn many new things about the industry and the current requirements of companies. This training proved to be a milestone in our knowledge of present industry. Every say and every moment was an experience in itself, an experience which theoretical study cant provide.

II

ACKNOWLEDGEMENT

It is my pleasure to be indebted to various people, who directly or indirectly contributed in the development of this work and who influenced my thinking , behaviour and acts during the course of study. I express my sincere gratitude to Dr. Rajiv Khanduja worthy principal for providing me an opportunity to undergo summer training at DLW,VARANASI(U.P) I am thankful to Er. Sushil Kumar Sharma, HOD ME for his support, cooperation, and motivation provided to me during the traning for constant inspiration, presence and blessings. I also extend my sincere appreciation to Er. A.S. Channi ,Er. Sumit Kumar & Er. Vikas Kumar Training Committee Coordinator, who provided his valuable suggestions and precious time in accomplishing my training report. Lastly, I would like to thank the almighty and my parents for their moral support and my friends with whom I shared my day-to day experience and received lots of suggestions that my quality of work.

Raj mohan rai

III

CANDIDATES DECLARATION

I, Raj Mohan Rai, Roll No.4110640, B.Tech (Semester- V) of the Yamuna Institute of

Engineering & Technology, Gadholi (Yamuna Nagar) hereby declare that the Training Report entitled A Comparative Study of Operational & Financial Efficiency is an original work and data provided in the study is authentic to the best of my knowledge. This report has not been submitted to any other Institute for the award of any other degree.

Raj Mohan Rai (Roll No.4110640) Place: yiet hostel Date:

IV

A BEREIF OVERVIEW

ABOUT DLW
Diesel Locomotive Works (DLW), an ISO 9001, ISO 14001 & OHS 18001 Certified Organization, 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 and dedicated to the nation. DLW is one of the few integrated loco builders in the world. It manufactures locomotives which are variants based on the original ALCO designs dating to 1960sand the GM EMD designs of the 1990s. This unit produces diesel-electric locomotives and DG sets for Indian railways and other customers in India and abroad. Installed Production Capacity - 150 Locomotives/ year :Total Staff - 5936 (as on 01.06.09) Total Production - 5577locos, 53 DG Sets (up to June 2009)

Silent Features
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. Unbeatable trail-blazing track record in providing cost-effective, eco-friendly and reliable solutions to ever increasing transportation needs for over four decades.

 A large base of delighted customers among many countries viz. Myanmar, Sri Lanka, Malaysia, Vietnam, Bangladesh, Tanzania, Angola, to name a few, bearing testimony to product leadership in its category.

Fully geared to meet specific transportation needs by putting Price - Value Technology equation perfectly right.

PRODUCTS
Its manufacturing facilities are flexible in nature. These can be utilized for the manufacture of different design of locomotives of various gauges suiting customer requirements and other products. Specifications and details of current products:

ALCO

1) BROAD GAUGE MAIN LINE FREIGHT LOCOMOTIVE: WDG 3A

Diesel Electric main line, heavy duty goods service locomotive, with 16 cylinder ALCO engine and AC/DC traction with microprocessor controls.

Wheel Arrangement Track Gauge Weight Length over Buffers Wheel Diameter Gear Ratio radius of Curvature Maximum Speed Diesel Engine

Co-Co 1676 mm 123 t 19132 mm 1092 mm 18 : 74 Min 117 m 105 Kmph Type : 251 B,16 Cyl.V

HP Brake Loco Train Fuel Tank Capacity

3100 IRAB-1 Air, Dynamic Air 6000 litres

2) BROAD GAUGE MAIN LINE MIXED SERVICE LOCOMOTIVE :

 WDM 3D

Diesel Electric Locomotive with micro processor control suitable for main line mixed Service train operation.

Wheel Arrangement

Co-Co

Track Gauge Weight Max. Axle Load Length over Buffer Wheel Diameter Gear Ratio Maximum Speed Diesel Engine

1676 mm 117 t 19.5 t 18650 mm 1092 mm 18 : 65 120 Kmph Type: 251 B16 Cyl. V type(up rated)

HP

3300 HP (sta ndard UIC condition)

Transmission

Electric AC / DC

Brake Loco

IRAB-1 Air, Dynamic , Hand

Train Capacity

Air 5000 litres

 EMD

1).WDG4 - 4000 HP GOODS LOCOMOTIVE

Broad Gauge freight traffic Co-Co diesel electric locomotive with16 Cylinder 4000 HP engine, AC-AC transmission, microprocessor controlled propulsion and braking with high traction high speed cast steel trucks. First turned out in 1999with transfer of technology from General Motor (USA), this locomotive has exceptional fuel efficiency and very low maintenance requirements. The heart of loco Traction Control Converter uses the GTO devices (obsolete technology). Now the IGBT devices, has been introduced from Oct 2006. It is the latest technology and will be cost effective and gives higher reliability. The locomotive power has been upgraded to 4500 BCV and the first Loco (Loco No 12114) was manufactured in May 07.

Diesel engine:

 16 Cylinder 710 G3B, 2 stroke, turbocharged after cooled Fuel Efficient Engine Injection System Direct Unit Injector Governor: Woodward Compression Ratio- 16:1 Lube Oil Sump Capacity: 950 Lts

Transmission : Electrical AC-AC 6 Traction motor ( 3 in parallel per bogie) Suspension - Axle hung / taper roller bearing Gear Ratio - 90:17

2). WDP44000 HP PASSENGER LOCOMOTIVE :-

State-of-Art, Microprocessor controlled AC-AC; Passenger Locomotive Powered with 16710G3B 4000HP Turbocharged two strokes Engine. Fabricated rigid design under frame, two stage suspension, and High Traction High Speed 3 axle (HTSC) light weight cast truck frame attribute to high adhesion performance. First turned out in 2003, this locomotive has

exceptional fuel efficiency and very low maintenance requirements. It is specifically designed for heavy haul passenger traffic requirements for Indian Railways The WDP4 fleet is being upgraded by provision of hotel load feature along with power up gradation to 4500 HP.

Diesel Engine : 16 Cylinder 710 G3B, 2 stroke, turbocharged after cooled Fuel Efficient Engine Injection System: Direct Unit Injector Governor: Woodward Compression Ratio- 16:1 Lube Oil Sump Capacity: 1073 Lts.

Transmission : Electrical AC-AC 4 Traction motor ( 3 in parallel per bogie) Suspension: Axle hung / taper roller bearing Gear Ratio: 77:17

::DG SETS::

DLW manufactures DG sets using DLW built engines. These DG sets are suitable for standby as well as base load applications and are seismically qualified. Alternators used are the stateof-the-art brushless type with static AVR. Control system is PLC based, with fault diagnostic feature. The alarms and shut downs can be customized as per requirement.

Engine

ALCO- 251

Power Rating

800 KW, 1500 KW, 1750 KW, 2000 KW, 2200 KW, 2400 KW.

Speed of engine

1000 rpm

Cooling arrangement

Radiator/ Heat exchanger

Control system

PLC based

Starting system

Air motor/ DC motor

Some other products that are manufactured according to demands of customer and are exported are:

WDM2 WDM3A

2600 HP BG mixed traffic.

3100 hp AC/DC BG Mixed Traffic.

WDP1

2300 hp BG Intercity Passenger (140 km/h).

WDG3C

3300 hp AC/ DC BG Freight.

YDM4

1350 hp MG Mixed Traffic

*Note: Nomenclature (Naming) of DLW Locomotives: D Diesel Type. W Wide (width of gauge).

G Goods. P Passenger. M Multipurpose. x Any numbers in the name represent the horsepower (hp=x1000). A100 hp. B200 hp. C300 hp ; and so on...

Hence WDG-3A stands for Wide Diesel Goods- 3100 hp engine & WDP-4 represents Wide Diesel Passenger- 4000hp

Organization
DLWS Vision: To be a World class manufacturer of Diesel Electric locomotive. Their Mission: We shall achieve our vision through Continuous Improvement in the
areas of Product Quality, Research and Development, Supplier Partnership, Human Resource Development and Team Work with emphasis on Core Competence Leading to Customer Satisfaction And Business Excellence.

Quality Policy: We are committed to Excellence in all Activities and Total

Customer Satisfaction through Continuous Improvement in Quality of Products and services.

Manufacturing Process

 Block Division Flame Cutting of Components

Steel plates 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.

Fabrication of Engine Block

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. After complete welding weldment is stress relieved and marking is done for subsequent machining.

 Engine Division

 COMPONENT MACHINING

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 Shop shave dedicated lines for operations like turning, milling, gear hobbling, 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 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.

Engine Assembly & Testing

Pre-inspected engine block, crankshaft, camshafts, cylinder liners, pistons, connecting rods, cylinder heads, exhaust manifold, turbo-supercharger and all related piping is used in assembly of engine. Electrical machines like traction alternator, auxiliary generator and exciter are thereafter coupled on the engine. The complete power pack with electrics are tested on Computerized Engine Test Beds to verify horse power output. Vital parameters of engine are checked to assure the quality of product .Only after the engine parameters are found perfect the power packs are cleared for application on locomotives.

 Vehicle Division: 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 drivers control stands is done in another work area.

 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 areas are tested radiographically. Welder training and their technical competence are periodically reviewed.EMD 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.

BOGIE MANUFACTURING
Special purpose machines are utilised 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, wheel sand axles, brake rigging and traction motors are assembled which is ready for application to locomotive.

 LOCOMOTIVE ASSEMBLY
Tested engines are received from Engine Division. Similarly under-frames are received from Loco frame Shop and Assembled trucks from Truck Machine Shop. 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. 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 painting all locomotive systems are rigorous tested as per laid down test procedures before the locomotive is taken up for final painting and dispatch.

Recent Milestones and Future Plans Milestones achieved :

1.Transfer of Technology Agreement

o DLW entered in an agreement with General Motors of USA (now EMD) for technology of transfer to manufacture high horse-power 4000HP AC-AC GT46MACand GT46PAC locomotives in India.

o Only country outside North-America to have this leading edge technology.

2.Locomotive design projects

o WDG4 locomotive with IGBT base TCC (Siemens & EMD) turned out. o Indigenous AC-AC control for WDG4 (with distributed power controls). o Indigenous AC-AC control for WDP4 (with hotel load capability). o WDP4 locomotive with IGBT base TCC & Hotel load capability.

Future Plans:

1.Assimilation of 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.

TRAINING PERIOD
Following four workshop were assigned to me during my training period of four weeks:

Heavy Welding Shop (HWS) Light Machine Shop (LMS) Truck Machine Shop(TMS) Sheat metal Shop(SMS)

HEAVY WELDING SHOP

In heavy welding shop steel sheets of about 75mm are welded together. To form engine block for both ALCO and GM engines. The conventional form of manufacturing engine blocks of such enormous size would have been very uneconomical. The three main type of welding are:

Submerged Arc Welding (SAW)

Shielded Metal Arc Welding (SMAW)

 Gas Metal Arc Welding (GMAW)

This shop mainly deals with the fabrication of the engine block and base (B.G. & M.G.) Turbo support. After cooler housing items. The engine block is the principal, structural member of the diesel engine. It is composite weldment with heavy plates thickness varying from 16 mm to 75 mm and steel forgives conforming to specification is 2062.The spine being the most highly stressed item as we can say spine of t h e c y l i n d e r b l o c k i s m a d e o u t o f o n e p i e c e b i t t e d 5 x 7 t h i c k n e s s confirming to is 1895. The billet foundation plate and cylinder walls are built around the steel forging saddles to form the air chambers which ensure the maximum rigidity for successful fabrication of cylinder block special attention is paid to the following aspects cylinder block special attention is paid to the following aspects. 1.Inspection standard 2.Proper materials 3.Proper electrodes and flux 4.proper welding technique 5.welfare of staff

SEQUENE OF FABRICATION OF ENGINE BLOCK

Set up of saddles foundation plates and spine on special fixture weld saddles spine founded on rails. Set up welding of outside cylinder wall. Set up of middle dock (Tack welded) with respect to target. Remove can bearing shim from saddle face.

and

Intermediate machining operation remark in middle deck and chamber at top of spline. Set up of inside wall and deck welded with spline. La y out of plane height.

 Intermediate machining Operation M a c h i n e h e i g h t o f o u t s i d e w a l l a n d i n i d e w a l l w i t h r e s p e c t t o marking and camber. Set up of top deck (Both side) and lifter block (G.E. side only) f o r filament of eye bolt and tack weld. All inside (8x2 Beal welds) welding in done by sub are method. Back gauging of saddle to foundation rail joint. Lay out for bearing. Set up for cam bearing with respect to pay out Si No.12. Welding of the cam bearing and saddle with foundation rail bottom side (back gauge portion) Set up of cam bearing rids and weld. Say out for 8 machining. Intermediate machining operation. Flame cut counter of foundation plate to give relief clearance to free movement of counter with respect to crank shaft. Set up of the side sheets and sub arc weld of side sheets and top deck. Set up of full control compartment sheet and weld. Intermediate machining operation mills both and to lay out for end plates considering total length and machining allowance. Hydrostatic test of water compartment. Set up of top end plates and weld. Set up of top deck center and weld. Stress relieving weldment. Kerosene oil test for control shaft compartment. Shot plast. Final debarring. Note: Saddle out side and inside walls foundation rail are x ray joints.

ELECTRODE :Saddle, spline and foundation plates are sledded on a rotary fixture E6020 electrodes 6.3 mm and 5 mm of M/s A Par Pvt. Ltd. Bombay and celorex of M/s Advani or Liken capable of giving X-Ray quality jointsare being used for the welding. T h e c o a t i n g i s s u c h t h a t a s t a g e c o n t a i n i n g i r o n o x i d e , m a n g a n e s e oxide and silicon is usually produced other constituents containing the

oxides of aluminum manganese of sodium are prevent to modify the slag ferromanganese in the main de-oxygen and sodium silicate is used as the binder. In most cases core wire is of remounted steel.

CARE OF ELECTRODE :Saddle spline rotary fixture E-6020 electrodes 6.3 mm and 5 mm.Arc welding electrodes require special care in handling and storage toThat the flux coating may retain its original strength of bonding over Long periods and give satisfactory welds on use so there electrodes are Keptin a store maintains its room temperature at least 10 to 20 c Higher then the outside temperature. When the storage atmosphere In humid the moister gets deposited in the minute pores of the flux Coating. Stocking electrodes certain directly on the floor should be Avoided as also putting too many of them once above the other because the electrodes at the bottom may get crushed. Due to the weight above. It is good practice tos t o c k . E l e c t r o d e s s h e l v e s s e p a r a t e l y a c c o r d i n g t o t h e i r s i r e s t yp e s a n d batches.

FLUX: In D.L.W. auto melt gr I flux of advance linken (P) LTD. Bombay In used. The flux in a mixture of power of determined practical size and each particle in chemically basic in character these particles are not fused. the flux in heated period to use in on over at 250 c for O2hours as moisture flux generated the hydrogen in the arc and cause cold cracks in the weld deposit and in the heat effected zero. WIRE:-Wire used in the sub are welding is the auto melt gr. A cold copper Coated size 5m.m. with low carbon

content confirming to IS 2879 Manufactured by M/S Advani lincon P. ltd. Bombay.The chemicalc o m p o s i t i o n o f t h e w i r e i n c a r b o n 0 . 0 8 % m . m . 0 . 4 6 % P . 0 . 0 1 8 % S0.022%.

STRESS RELIVE OF CYLINDER BLOCK

After completion of welding the cylinder block in then stress relievedat the temp. Ranging from 115 F obtating total timing 28 Hrs ie. (1)Pre heat time 14 Hours. (2)Soaking time 04 Hrs and (3)C o o l i n g t i m e 1 0 H r s i n s t r e s s r e l a t i v e s f u r n a c e accommodate to B.G. block at a time. As the capable to

engine block in

ma c h i n e d t o v e r y c l o s e t o l e r a n c e s . I t i s n e c e s s a r y t h a t a l l stresses developed during the fabrication stages are completely relieved before machining. This would ensure a longer life in service without any distortion which would normally result on a c c o u n t o f v e r y a l t e r n a t i n g s t r e s s e s t h a t t h e e n g i n e b l o c k i s subjected to during its service.

KEROSINE OIL TESTCheck that there should not be any leakage at the bottom side of the fuel control compartment welding joint after powering kerosene oil. The engine block is then shat blasted at pneumatic compressed air a pressure of 75ibs/sgu .inch.

DEBURINGIt is to be ensured that the completes (welding) weldment is free of any spatter welding defects and sharp corrosion of important welded joint have been ground then the cylinder block is marked and handed over for machining operation to H.M.S.

DESINING RECOMBINATION FOR CAMBEARING SUPPORT :Earlier design of cam bearing support welded with cylinder side waitsthen welded with the ribs (3/4Th welded grc) due to heavy vibration and less welding area development of cracks wire observed in the com . (Mainly upper portion)T o o v e r c o m e t h e p r o b l e m o f c r a c k s a n d s t r e n g t h e n n e w d e s i g n o f cam bearing are welded all round with the ribs and then ribs are wide with the side cylinder wall. Hydrostatic testW a t e r c o m p a r t m e n t a r e f u l l y f i l l e d w i t h w a t e r a n d a f t e r a i r l i g h t cover ing are pressure of 75 lbs/squ inch minimum is maintained for about half on hours. It there is any leakage in welds arranged welded and water listed. Heavy weld shop

1.Heavy weld shop ha three important sections. 2.Flame cutting, grinding and straightening section. 3.Cylinder blocks fabrication section. 4.Main base, turbo support and miscellaneous section. Flame cutting, grinding and straightening section All the flame cutting items required for the B.G. & M.G. engine for block, base & turbo support are cut in the section by flame cutting machine. For all cutting of different types of items. The different types of plates are use as per their specification and thickness. Following important items are cut here. Spline, top deck, middle deck side sheet, main base and plates top railcross web, back, plate, centers block flanges levers etc. I n g r i n d i n g section A b o v e i t e m s a r e d e s l a g e d a n d g r o u n d b y p n e u m a t i c Grinder. In straighten section important items of cyl-block main base and turbosupport are straightened. Cylinder block fabrication section The following components for B.G. Cylinder block assly are required. 1 . E n d s e a l 2.Side plate L.S & R.S. 3.Angle L.S. & R.S. 4.Foundation plate L.S. & R.S. 5.Saddle machined inters main bearing I no. 6.Saddle machined gen end I no. 7.Saddle machined centre main bearing I no 8.Spline I no 9 . C yl s i d e w a l l o u t s i d e L . S . & R . S . 10.Cyl side wall in side G.S. & R.S. 11.Middle deck L.S. & R.S. 12.Cam bearing (inter, gen and & frill end ) 18 nos 13.Cam ribs 18 nos 14.Top deck L.S. & R.S. and top deck centre 15.Weld strip (gen-end) R.S. & L.S. 16.Plate ( water compt drive) 17.Frill end plate. 18.Self cont. compt L.S. & R.S. 19.End plate ( gen end)

20.Cover (cont compartment ) 21.Diaphragm 22.Lifter block ( gen end)

Sequence of Fabrication Assembly:

Setting of saddles on the fixtures as per drawing with the foundation plat L.S. & R.S. and one spine on the top of the saddle. Tacked and weldedall these with each other burn run of the saddle with spline, clean and grind the opening of the spline, then set and face the outside and inside walls L.S.& R . S . b o t h s i d e s o f t h e s a d d l e b u r n r u n o f f a n d c l e a n g r i n d o f t h e w a l l opening After that setting up the middle deck weld from bed bottom side of d e c k a n d l i f t e r b l o c k w e l d 1 6 b e e t s a l l w e l d i n g a s q u a l i t y . S a d d l e t o foundation plate, saddle t o s p l i n e a n d s a d d l e t o o u t s i d e w a l l w e l d i n g i s check as joints. Arc wilding done machine on the cylinder block where the welding by machine is called submerged are welding. Copper coated mild steel class II were with flux is used. After x-ray welding test, the assembly is sent for lay our of cam bearings in marking section. The cambering are set up tack and weld with the cam ribs and water compartment plates. After that again x-ray text of bottom plates is done. Then burn opening and Skelton grinding operation is done. Then send this block assembly in the machine section for 8 machining of side sheet. Set and weld the side sheets on the 8 machining. Weld fuel self compartment on the positioned welding machine. Weld side sheet foundation rails. Side sheett o c a m r i b s . O u t s i d e w a l l o f f u l l s e l f c o m p a r t m e n t . A f t e r t h a t t h e b l o c k assembly is again sent to M/C section. For end milling to maintain the length of the block as per marking and size. Then hydraulic water test is done at 75P.S.I.At last set up the end plates (gen and free end) both side of the block assembly, tack and then setup the top deck centre in the centre of the block and weld it by sub are welding M/C After complete fabrication the block is sent to H.T.S. sec. for stress relivingto 700 c then shot blasting the block and sent the machine section for final machining. Main base fabrication The following components are required for the assly of main base. 1.Side sheet L.S. and R.H 2.Pipe assembly with plates 3.Engine mount free end and gen end CH/RH 4.Rib (engine mount free end & gen.end)

5 . T o p

r a i l

6.Bottom. Plate (Gen end, free end & centre) 7.Plug L.O. drain. 8.Cross web G.A. 1,2,3,4,5,6,7,8, & 9 9.Cross web auxiliary assembly 10.End plate free end & gen end. 11.Oil drain compartment. 12.Pad 13.Brass engine mount free end. 14.Brass engine mount gen end. 15.L.O. suction pipe (sub. Assembly)

Sequence of Fabrication:Setting top rails on the fixture and mach the centre of the fixture. Setthe side sheet R.S. & L.S. with the cross webs to maintaining the width of 31 of main base, tack and weld with cross webs. After that bottom plates genend and free end are set up. Tacked and weld on its proper place. Then set and tack and weld the end plates gen end & free end with lo suction pipe. At post L.O. drain plug is set up and dip strike on it proper place. Engine mount free end and generator end CH/RH, T, welding is to be completed. After fabrication, the main base is sent to H.T.S. for stress reliving at 700 c t e m p e r a t u r e a n d c o o l e d i n f u r n a c e . T h e n s h o t a n d d e b u r n . T h e n s e n t t o machine section for complete machining. TURBOSUPPORTFABRICATION:It is the support for turbo which is mounted on cylinder block on free end side. Following components are required for it. 1-Flange bottom 2

2-Back plate 1 3-Side plate l.s 1 4-Side plate R.H 1 5-Flange oil catcher 1 6-Top plate air chamber 1 7-Front wall air chamber 1 8-Bottom Plate 1 9-Centre Plate 1 10-Back wall pt. 1 11-side plate R.S 1 12-partition plate 1 13-patch plate 2 14-gasket 4 15-pipe segment 1 16-cover 1 17-ribs 1 18-flange 1 19-side pipes 2 20-side plate air chamber

PROCEDURE OF FABRECATION: Dressing and setting of flange bottom and back plate on support . Welding of the flange from the centre of fixture. Setting and tacking of back plate, buck wall and portion plate. Tacking of right side plate on back plate. W e l d i n g o f 2 I . P . S e x t r a h e a v y c o u p l i n g o n l e f t s i d e a n d i t s s e t t i n g and tacking on back plate. Grinding ,dressing , setting & tacking of centre on s i d e p l a t e R.S.&L.S Setting & tacking of flange oil catcher. Marking and gas cutting of 4 dia hole in bottom plate and welding of ring on the hole of the plate. Setting and tacking of above bottom P.t. on top plate on fixture. Setting and tacking of side R.S

 Dressing of back wall and its setting and tacking. Setting and tacking of front and bottom plate & front wall. Setting and tacking of pipe segment cover. Inspection hole cutting in front wall. Setting and welding of flange and side piece.

WELDING PROCESS o Outside bottom plate, top plate, centre plate to side plate both sides an rest welding is down from bottom is top in sequence numbest for inside welding bottom pt, top plate and rest, from bantam is tip is done o In this operation the support is clamped on positioned with top p l a t e a n d a l l t h e r e s t w a d d i n g i s c o m p l e t e d . A f t e r t h e s e gauging Is done on flange oil catcher. Then later welding is done and base is welding