ACKNOWLEDGEMENT

We hereby take this opportunity to thank those people who helped in my

training. This training gives me an opportunity to learn a lot of technical
things and knowledge about new technology.

Firstly I would like to express my deep gratitude & indebtedness to Mr.
ONKAR SINGH (SSE), whose supervision and hard-work contribute in my
training in Diesel Loco Modernization Works. He consistently helps me
and guides me in achieving the prime objective of my training.

I would like to thank to the workers of Diesel Loco Modernization Works
who always gave their full co-operation in helping me to understand what
I ask for.

Last but not the least the constant guidance and encouragement receiving
from T&PO Lt Col (Retd N$ Julka has been of great help in
undertaking training at Diesel Loco Modernization Works

2. CONPANY PROF!LE

HI$TORY
DMW was set up in 1981 with the assistance of World Bank. At that time
Industries in India were not fully developed to manufacture diesel engine
precision components to carry out the remanufacturing of various traction
machines & engine blocks. DMW started the components manufacturing in
1986 along with the remanufacturing of traction machines & engine
blocks. Need was also felt for rebuilding of locomotives to enhance
performance of locomotives by incorporating latest technological up
gradations and all RDSO modifications. It was expected that with the
rebuilding of locos after 18 years, the locos would become fuel efficient,
shall haul heavier loads and shall be fitted with latest modern less
maintenance intensive sub-assemblies and assemblies. Accordingly the
rebuilding was started in DMW in 1989. The shops which were set up for
component manufacturing and remanufacturing of traction machines and
engine blocks are under Phase-I of the project.
ABOUT U$

INTRODUCTION:-

O Introduction of Diesel Locomotives on the Indian Railways started in
late 50s, with the import of locomotives from M/s. ALCO, USA. With
the setting up of Diesel Locomotive Works at Varanasi in the year
1961, the addition to the Diesel Locomotive fleet started at a regular
pace.
O It was in the context of the need for high precision components for
maintenance support to the diesel fleet, that in the year 1979, a
decision was taken to set up Diesel Component Works at Patiala.
O The Foundation Stone of Diesel Component Works (DCW), Patiala
was laid on October 24, 1981 and production started in 1986. A
decision was also taken that DCW will do midlife Rebuilding of Diesel
Locomotives after a service life of 18 years. Accordingly, Phase-II of
the project was sanctioned and the work of Rebuilding started in
1989.

ROLE OF DMW IN THE GROWTH OF INDIAN

RAILWAY$:-

DMW had been rebuilding about 72 Locomotives from 1992-93 to 2005-
2006. To meet the challenges of increased traffic, DMW enhanced the
productivity of the workshop and was able to rebuild 86 Locomotives in
2006-07, 102 Locos in 2007-08 and 108 Locos in 2008-09.
DMW has achieved a Record Breaking Performance of Locos in
-

During rehabilitation, latest sub-assemblies like Microprocessor Control
System, AC-DC power transmission, Fuel Efficient Engine Kits, Roller
Bearing Suspension System and Traction Motors are fitted and up-
gradation of Horse Power of Locomotive from 2600 HP to 3100/3300 HP is
done. This ensures that the trip schedules of Locos are extended
to 30/40 days and Locos give better reliability, availability, improved
performance during service with better fuel efficiency.
$ALIENT FEATURE$ OF DMW:-
O I$O : & I$O : Certified Production Unit
O Total workforce on roll is 3783 including 87 officers.
O Workshop area (m
2
) 837936
O Covered area in shops (m
2
) 88194
O Township area (m
2
) 1416800
O Electrical energy Consumption (lacks of
units/year)
200
O Total staff quarters 1767
O No. of beds in Hospital 30

PRE$ENT ACTIVITIE$ AT DMW:-
4 Rehabilitation, up gradation & Modernization of Diesel Locos.
4 Supplying new Power Packs to Parel Workshop & Remanufactured
Power Packs to Zonal Railways.
4 Supplying Motorized Wheel sets to Zonal Railways.
4 Supply of rehabilitated Engine Blocks & Traction Machines to Zonal
Railways.
4 Supplying 240 types of high precision & critical components to
Zonal Railways as Maintenance support.
4 Nodal Agency for Rehabilitation of high HP Turbo.
4 Supply of all types of Carbon Brushes of Diesel Locos to Zonal
Railways.

WORK$HOP FACILITIE$ AVAILABLE AT DMW

$hops set up under Phase-I of the project are called
Manufacturing $hops:-

4 Light Machine Shop
4 Heat Treatment Shop
4 Traction Machine Shop
4 Heavy Machine Shop
4 Cylinder Liner Shop
4 Carbon Brush Shop
4 Plant Maintenance Shops
4 Tool Room

$hops set up under Phase-II of the project are called
Rebuilding shops:-

4 Loco Rebuilding Shop
4 Power Pack Shop
4 Bogie Shop

4 Air Brake & Pipe Shop
4 Loco Test & Paint Facilities
NATURE OF WORK:-

O DMW has turned out 04 nos. Locos after up-gradation from 2600
HP to 3300 or 3100 HP Microprocessor Control Rebuilt
Locomotives during the financial year 2009-10.
O The major modifications incorporated in these locos include 3300
HP Power Pack with 18mm Fuel Injection Pump, New Engine Block,
Microprocessor Control System, Microprocessor Control Governor,
Red Brass Mechanical Bonded Radiator for improved cooling, Roof
Mounted Dynamic Brake Resistance, capable for self-load testing to
dissipate 3300 HP during the self-load box.
O DMW Patiala has Re-built or upgrades some 2 units to class
3A (Old name is 2C) and 3C.

QUALITY, ENVIRONMENTAL AND OCCUPATIONAL

HEALTH & $AFETY $Y$TEM$:-

O DMW is ISO 9001:2000 certified by M/s. BIS, Chandigarh. The
certification is valid up to 09.05.2011. M/s. BIS have renewed the
certification of ISO 9001:2000 for a period of three years i.e. up to
09.05.2011.
O DMW including Hospital & Colony is ISO 14001:2004 certified by
M/s. BIS, Chandigarh. 3rd Surveillance Audit was conducted
successfully from 07.10.09 to 08.10.09. Recertification audit is due
and is likely to be conducted by May2010.
O M/s. BIS, Chandigarh has successfully conducted certification audit
for Occupational Health and Safety Management System
(OHSMS/IS 18001:2007) on 30th & 31 March, 2010 and the audit
team has recommended for certification.

8 HUMAN RE$OURCE DEVELOPMENT
O In the financial year 2009-10, TTC has conducted 44 Refresher
Courses and 02 Supervisor Development Course in which 426 Staff
and 66 Staff participated respectively. In addition, 04 First Aid
Training courses, 30 Fire Fighting Training courses and 10 Industrial
Safety courses have also been conducted.
O Training capacity utilization during 2009-10 has been 117.19%
which is an all time high so far.

PRODUCTION PERFORMANCE DURING -:-

During 2009-10, performance of DMW has been the best ever since its
inception. DMW has achieved highest production figures in all major areas
of activities, i.e. Loco Rebuilding, Power Pack Assemblies, Supply of
Motorized Wheel Sets, Remanufacture of Traction Motors etc.
DMW has rebuilt locos and achieved Turn Over of Rs 8
Cr in - - first time in its history
Production performance vis--vis Targets fixed for the year has been as
under: -

$
No
Item

Target
-

Out turn
-

%age
improvement
1. Locomotives
Rebuilt
8
2 Power Packs (for
ZRs

3. Power Packs
(Total
8
4. Motorized Wheel
$ets

5. TM assemblies
6. TM Magnet Frames
7. TM Armatures
8. Total out turn (in
Rs Cr
8

FUTURE PLAN$

4 To establish series manufacture of EMD Traction Alternators
4 To develop overhauling facilities of Siemens make Traction Motors
for EMD Locomotives
4 To remanufacture Traction Alternators and Traction Motors for
700HP & 1400HP & and Remanufacture of light weight
Traction Motors
4 Progressively increasing the outturn of 3300 HP Rebuilt locos

DMW I$ A VIBRANT AND PRE$TIGIOU$ UNIT OF INDIAN
RAILWAY$ LOOKING TOWARD$ FUTURE WITH CONFIDENCE AND
GEARING UP TO BECOME HUB OF ACTIVITY OF ALCO
LOCOMOTIVE$

TRAINING
RLPORT

POWER PACK $HOP (PP$

INTRODUCTION: -

O Power Packs from incoming locomotives are sent to the Power Pack
Shop for remanufacturing. Sub-assemblies such as power assembly,
vibration damper, cylinder head, lube oil and water pump are also
assembled in this shop. New Power Packs are also being supplied to
Parel Workshop.
O Power pack shop is an assembly shop. In this shop the power pack
(iesel electric engine) is wholly dismantled, rebuilt, tested and
then sent to LRS for fitment on the loco. The function of the shop can
be broadly classified into following two types: -
. Dismantling, reconditioning and assembling of power pack.
Load testing, specific fuel consumption testing and other types of
testing.
O The old 2C diesel electric engine is upgrades to class 3A
and 3C in power pack shop. The power of diesel electric engine
is upgrades from 2600HP to 3100HP or 3300HP.

PROCE$$ LAYOUT OF POWER PACK $HOP: -

$TRIPPING
TG
ENGINE BLOCK
TRACTION
MACHINE $HOP
HM$

POWER PACK
A$$Y D
ENGINE BLOCK
A$$Y ON
MANUPULATER
ENGINE
BLOCK
POWERE PACK TE$TING
ON TE$T BED D+
POWER PACK TO
LR$ D+
D
OLD POWER PACK FROM LR$

LOCO$ NOMENCLATURE: -

Locos, except for older steam ones, have classification codes that identify
them. This code is of the form gauge], 5ower], load], series],
subty5e], suffix]".
O In this the first item, gauge], is a single letter identifying the
gauge the loco runs on: -
= Broad Gauge
= Meter Gauge
= Narrow Gauge (2 6")
= Narrow Gauge (2)
O The second item, 5ower], is one or two letters identifying the
power source: -
= Diesel
C = DC traction
A = AC traction
CA = Dual-power AC/C traction
= Battery electric(rare)
O The third item, load], is a single letter identifying the kind of load
the loco is normally used for: -
= Mixed Traffic
P = Passenger
= Goods
S = Shunting
L = Light Duty
& = Multiple Unit (& / &)
R = Railcar

O The fourth item, series], is a digit identifying the model of the

loco. Until recently, this series number was simply assigned
chronologically as new models of locos were introduced.


O The fifth item, subty5e], is an optional letter or number (or two
of them) that indicates some smaller variation in the basic model or
series, perhaps different motors, or a different manufacturer. With
the new scheme for classifying diesel locos, the fifth item is a letter
that further refines the horsepower indication in 100h5 increments:
A for 100h5, for 200h5, C for 300h5, etc. So in this
scheme, a 3A refers to a 3100h5 loco, while a 3F
would be a 3600h5 loco.


O The last item, suffix], is an optional indication that indicates
something special about the loco, such as a different gearing ratio
or brake system than usual.


So, 3A is a Broad Gauge (), Diesel (), Mixed Traffic (),
3100 HP locomotive (diesel electric engine). Similarly 3C is
a 3300 HP locomotive.

UP GRADING: -
Old diesel electric engine (2C) is upgrade to new diesel electric
engine (3A/3C) in power pack shop. To increase the power
from 2600h5 to 3100h5/3300h5 various up gradations are done witch
are given below: -
+ Cylinder head:
Advantage: -Water capacity is more in 251+ cylinder heads which
provides better cooling earlier there were casting holes in the
cylinder heads but now the holes are drilled to increase circulation.
$tiffer unit camshaft with fuel injection at degree BTDC:
Advantage: - Stiffer lobes are designed to with fuel injection
pressure 1200 bar. Segment dia. is larger & fitment from the FIP
support window. All the left & right side segment are common.
Dampers are removed & cam gear is supported at both ends
instead of cantilever type arrangement.
Increase the dia of FIP (fuel injection pump plunger up to
mm
Advantage: - With this change more fuel goes to the chamber &
more power will be produced.
Capacity of cylinder head water jacket increased
Advantage: - The increased capacity of cylinder head water jacket
increases the cooling power.
Crown shape piston with steel cap & aluminum base
Advantage: - In 2600 HP () the concave shape of the piston is
designed. With this shape more fuel injection is there & less
compression is there. But in 3300 HP () the piston is crown
shape. With this shape less fuel injection & more compression .the
advantage of two parts i.e. steel cap is resistant of more heat &
aluminum base is reduced weight.

Increase the water pump impeller diameter up to 10"

Advantage: -By increasing the water pump impeller diameter from
9" to 10" more water is circulated. Hence better cooling is now
achieved with bigger water pump impeller.

Cylinder head with 30

degree valve seat of angle of inlet
valve: - Cylinder valve seat angle has been reduced from 45
0
to
30
0
. It provides a line contact between valve & the cylinder head
valve seats.
Advantage: - Better compression is achieved by reducing the
angle. Also there are lesser chances of leakage and also with this
scavenging action better & sturdier valve.
8 Modified fuel header with two additional supports at the
end: - The fuel header is that pipe which supplies fuel to fuel
injection pump (FIP) through the fuel jumper. Earlier it has only
one support, which is at the center of the fuel header. Now two
additional supports are provided at the ends of the fuel header.
Advantage: - Proper fastening, lesser vibration, lesser chance of
leakage and failure.
9. Modified strainer housing with 3 inch piping replacing 2.5
inch.
Advantage: - More discharge is achieved by replacing the 2.5"
pipe by 3" pipe. Better lubrication & cooling is now achieved.

Alternator is used in place of generator
Advantages: - Alternator is used in place of generator because
with generator there is C supply. Generator & exciters are used to
convert this C supply into AC & given to the traction motor under
the bogies. During this transmission there is losing of energy. So to
reduce this energy lose generator is replaced by alternator.

PROCEDURE OF WORK: -
























MAIN A$$YMBLY
CYL HEAD,
CAM $HAFT,
PI$TON A$$Y
ETC

BLOCK A$$YMBLY

TE$T BED

FIP INJECTER$

CONTROL $HAFT, FIP
$UPORT, PUMP$ ETC

LUBE OIL PUMP TE$TING: -

To ensure that proper fitment of lube oil pump's component for its smooth
functioning, the testing of lube oil pump is done before fitment.
For this purpose lube oil pump test bench and Ring spanner 15/16" and 7/8"
apparatus are used.
PROCEDURE: -
Check Lube oil pump assembly for free rotation manually.

nstall lube oil pump assembly on test rig.

Check free rotation of motor manually.

Fit lube oil connection between lube oil pump outlet and filter
Drum.

Open the gate valve of lube oil storing tank to supply lube oil in the sump.

Start the motor and run the pump on first speed.

Change the speed at equal intervals of 5 minutes each from 1st to 4th speed.

Run the motor in 4th speed for half an hour approximately for proper circulation of
lube oil

Maintain the pressure in between 3 to 4 kg/cm2 by partially closing the out let gate
valve.

Run the pump for approximately 4 hours and observe the following parameters, if
any of these problems exist, remove the pump from test bench and rectify before
testing it again:
a) Any abnormal sound
b) Any leakage of lube oil from blow holes or cracks of pump casing and face
plate end.
c) Run the LOP at 100F & pressure 3.5Kg/Cm2 for 30 minutes and check
leakage/abnormal sound.
d) Run the LOP at 104F and pressure 6 Kg/Cm2 for 15 minutes and check
leakage/abnormal sound.
e) Run the LOP at 125F and pressure 3.5Kg/CM2 for 1 hrs. and check
leakage/abnormal sound.
f) Run the LOP at 150F and pressure 3.5kg/Cm2 for 1 hrs. and check
leakage/abnormal sound.

TG (TRACTION GENRATOR FITTING AND CRENCK $HAFT: -
EQUIPMENT$ U$ED:-

S. NO. EQUIPMENTS RANGE
1. Feeler gauge 12" length

.003" to .025"
2. Deflection gauge 13/8"

3. Torque Wrench 7501400 ft.lbs

TABLE -
PROCEDURE: -
Re tap 12 nos. flanges bolt holes of traction generator.
Attach sling and mount generator on crank shaft flange.
Apply crank shaft coupling bolts and washers.
Apply generator mounting shims and cap screws and secure
generator to engine block.
Remove cardboard strips from space b/w armature and field poles.
Tighten bolts securing generator to engine block and base at 1150
ft.lbs torque.
The coupling bolts of crank shaft to generator flange should be
tightened crosswise with 800 ft.lbs torque.
Fix deflection gauge at center punch mark b/w webs of crank pin,
sure that the gauge is parallel to shaft in horizontal and vertical
plane at bottom.
Rotate crank shaft clockwise and counter clockwise, check deflection
at five position, left top, left bottom, right, right top (limit less
then +.001").
If deflection exceeds permissible limit then correct it by apply or
remove shims from the generator bolting pad until the deflection is
within limit.

WATER PUMP A$$EMBLY: -

The scope of this section is to ensure the proper fitment of water pumps
components for its smooth functioning.
EQUIPMENT$ U$ED: -

$.
No.
EQUIPMENTS $!
VALU
TO ALULAT
1. Dial gauge with magnet
base
0.0034 ax. Run out of the
impeller
. Torque wrench range 0250
ft. lbs.
125 ft. lbs Torque Impeller nut
. Dial indicator gauge 0.006" -
0.018"
Backlash between
water pump gear
and extension shaft
gear.

TABLE-
PROCEDURE: -

Check all the components for deburring and cleaning of all threaded
holes and oil passages.
Press both side bearing No. 6311 and 6312 on the shaft by hydraulic
press.
Press ring sleeve for oil seal on shaft towards and on bearing No. 6311.
Fit the bearing retainer plate towards gear end. Tighten the screws and
wire locked.
Check inner dia. of drive gear and outer dia. of the shaft to obtain a
matching set with interference of 0.0005" - 0.0015".
Shrink fit drive gear (W.P.) on shaft with key and tighten the gear nut.
Lock this nut with screw and wire.
Hand press the oil seal into the frame bearing against the bearing inner
race No. 6311 and fit slinger over it.
Fit 3/8" stud (8 os.) on frame bearing and install the seal plate with
its gasket. Tighten 3/8" nylock nut to secure steel plate.
Press water seal mating ring assembly into the counter bore and install
water seal assembly over the ring.

Fit taper cut sleeve in impeller. Fit key on key way of the shaft and then
push fit the impeller assembly on the taper portion of the shaft.

Fit castle nut with plain washer. Tighten the nut to 125 ft. lbs. Torque
and apply the cotter pin.

Check the run out of the impeller with help of dial gauge. It should be
0.0034".
Drive " stud 8 os. in water pump casing and install the frame
bearing complete assembly on it with gasket. Tighten the nylock nut to
protruding out one thread of the stud.

Fit 1" drain plug.

Check the pump for its free rotation.

COMPONENT$ FAILURE PROBLUM$: -

The failure of parts or components can create a major problem. There are
some failures and action by DMW witch shows below: -

$
NO
FAILURE
REPORTED
FAILURE
ANALY$I$
ACTION BY
DMW
1. Failure of
piston/linear
4 Improper
clearance
between piston
and linear or
sleeve and
linear,
4 Due to con-rod
linear failure,
4 Lubrication
starvation.
4 100% use of
linear Go gauge,
4 RDSO has revised
to3RV
Piston/linear cold
clearance from
.250mm
to.300mm.

2. 4 Water pump
impeller nut work
out,
4 impeller free on
shaft,
4 Water leakage
from tell tale hole.
4 Water pump
shaft design
problem,
4 Quality of water
seal.
4 Sleeve less
stainless steel
shaft design
implemented.
4 Drawings of shaft
&impeller have
been revised to
provide
interference of
.07mm to
.015mm.
4 Water seal being
procured only
from approved
sources.
3. Failure of exhaust
manifold.
4 Breakage of
exhaust manifold
at 6, 7 and 8
th

location.
4 100% new
exhaust manifolds
are fitted.
4 Final tightening of
segments with
each other is
being done after
tightening with
cylinder head.

$
NO
FAILURE
REPORTED
FAILURE
ANALY$I$
ACTION BY
DMW
4. 4 Cracking of fuel
injection tube,
4 Fuel leakage from
banjo bolt.
4 H.P. tube crack.
4 Rigidity between
fuel inlet jumper
& fuel oil header
&FIP after
tightening.
4 Fixed size of Cu
washers.
4 Copper washers
are annealed
before fitment
and banjo bolts
are torque at 25
ft lbs.
4 Copper washers
of different
thickness as per
RDSO have been
introduced to
ensure selective
assy.
5. Connecting rod
breakage.
4 Over weight
forging.
4 Rifle hole taper
weakening wall
at small end.
4 Low Izod value.
4 100% weight
checking.
4 Reducing cutter
redesigned.
4 Proper alignment
of gun drill hole.
4 Torque/elongation
of con-rod being
done at specified
level before
boring and re-
assembling.
4 Rifle hole
operation started
on new CNC
WDMA.
6. Traction Alternator
deflection out.
4 TA dowel hole to
foundation rail
distance found
less.
4 HMS advised to
maintain the
distance from
dowel hole to
foundation rail
with in 10thou.
4 Care fullness
while carrying
out TA
deflection.

TABLE -

PARAMETER$: -
Some standard values of different parameters for new diesel electric
engine (3A/3C) and old diesel electric engine (2C)
are show in the table: -

TABLE -


ENGINE
CAPACITY
HP
(WDMC
HP
(WDMA
HP
(WDMC
ENGINE: -
Power output
to traction
2250 HP 2750HP 2950HP
SFC (sufficient
fuel
consumption)
156gms/BHP-hr 156gms/BHP-
hr
154gms/BHP-
hr
RPM (rev. per
minute)
1000 1050 1050
OST(over
speed time)
setting
1120 1200-1210 1200-1210
Peak firing
pressure
1800 PSI 1950 PSI 1920 PSI
Rack 26 mm 29.5 mm 28 mm
FIP (fuel
injection
pump)
plunger
15 mm 17 mm 18 mm
Camshaft FE design Same Stiffer unit
camshaft
Fuel injection
timing
25.5 BTDC 25.5 BTDC 22 BTDC

TABLE -


ENGINE
CAPACITY
HP
(WDMC
HP
(WDMA
HP
(WDMC
FUEL
INJECTION
TUBE$: -

Cylinder
heads
45/45 VSI
angle
30/45 VSI
angle
30/45,251+design
with bigger &
stream lined
water jacket
Piston & comp
ratio
Steel cap
12.5:1
Steel cap
11.75:1
Steel cap 11.75:1
Water pump 9 impeller 10 impeller 10 impeller
Fuel oil filter Std. Std. Long life filters
recommended
Turbocharger GE 21sq
nozzle/ ABB
VTC 304 2600
HP
GE 21sq
nozzle/ ABB
TDR 01
3100HP
GE 22.5 Sq
nozzle/ ABB TPR-
61
After coolers Modified after
cooler
effectiveness
70%
Modified A/C
effectiveness
70% or twin
A/C for GE
Twin A/C for GE
turbo or high
Eff.>90% mod.
A/C

8 TORQUE VALUE$: -
Torque values for component parts are different. These torque values are
shows in table below: -

$ NO COMPONENT PART TORQUE VELUE$
IN 'ft.lbs'
1. Cylinder head nuts 550
2. Water inlet elbow 75
3. Gear crank shaft 300
4. Cyl. head stud at full
Engagement
120
5. Con. Rod bolts: -
Preliminary
Snugging up
Elongation

20
100
0.022"

6. Impeller nut, water pump 125
7. FIP support cap screw 150
8. Cap screw at cam shaft 90
9. Cap screw, 1/2" air elbow to lock 75
10. Cap screw, 5/8" air elbow to
SPL nut at Cyl. hd.
150
11. Cap screw, 7/8" air elbow to strong
back
300
12. Fuel jumper bolt 30

TABLE -

BIBLIOGRAPHY

1. Daily Diary
2. www.team-bhp.com
3. www.irfca.org
4. www.railway-technical.com