Dlw 4 Weeks Internship Report.docx

INTERNSHIP REPORT

DIESEL LOCOMOTIVES WORK, VARANASI

SUBMITTED BY ANSHAJ SINGH (B.TECH 2ND YEAR, MIT, MANIPAL)

DURATION OF INTERNSHIP- 4 WEEKS

Acknowledgement I take this opportunity to express my heartfelt thanks and gratitude to the employees and the officers of DLW, Varanasi for their help and support during training period. I would also sincerely like to thank Mr. Ramjanm Chaubey (Principal, TTC) for giving me such a great opportunity.

Table of Contents: 1. Introduction  History  Recent milestones  Locomotive production  Products of DLW 2. Production shops 3. Assigned areas 4. Locomotive Test shop (LTS) 5. Engine Test shop (ET) 6. Central Transport shop (CTS) 7. Sub Assembly shop (SAS) 8. Specialisation of work culture 9. Nomenclature of diesel locomotive 10. Engine 11. Conclusion 12. References

INTRODUCTION HISTORY The Diesel Locomotive Works(DLW) in Varanasi, India, is a production unit owned by IndianRailways, that manufactures dieselelectric locomotivesand its spare parts. It is the largest diesel-electric locomotive Manufacturein India. Locallyit is abbreviated as D.L.W.It is locatedin the Manduadiharea on the outskirts of the city of Varanasi. Diesel Locomotive Works is an ISO 9002 certified manufacturer of diesel electric locomotiveand is one of the biggest industrial complexes in eastern part of the country. It was set up in 1961 with technical collaboration from M/s. ALCO/USA with a modestbeginning of manufacturing 4 locos in 1964. Today DLW is the largest Diesel Locomotive manufacturer in the world, and the largest in Asia. In order to capture export market & widen itsproduct range. Indianrailway entered in to a contract for Transfer of Technology (TOT) withM/s. General Motors, USA for manufacture of 4000 HP state of the art locos at DLW. Afterassimilation of this technology,DLW will become the only factory in the world capable ofproducing ALCO as well as General Motors designs of locomotives.It is the only manufacturer of diesel –electric locomotive with both ALCOand General Motors Technologies in the world. DLW exports locos to SRILANKA , MALAYSIA, BANGLADESH, TANZANIA, VIETAN-NAM. RECENT MILESTONES  321 locomotives (including 25 electric locos) manufactured in FY 2017 18, amounting to 2% higher over Railway Board’s target.  In addition to above, First time in the world, DLW successfully converted two old diesel locos (WDG3A) into Electric loco (WAGC3). Converted loco will work as a twin loco consist (2 X 5000 HP) and comprises of one cab per loco.

 DLW has won the ‘Best Production Unit Shield 2017-18’ for 3rd consecutive year  This year DLW has obtained certification of NABL for laboratory and 5 S Workplace Management. Now DLW has the following certifications: - ISO 9001 - ISO 14001 - OHSAS 18001 - ISO 50001 - ISO 3834 - GreenCo Silver Rating - NABL Accreditation - 5S LOCOMOTIVE PRODUCTION

DLW has manufactured 8149 locomotives (all types) till 31st March 2018 since its inception of production. It includes 2359 HHP, 27 electric, 155 export and 577 locos for NRC.

PRODUCTS OF DLW

PRODUCTION SHOPS Production shops are divided in 3 divisions:  Block division  Engine division  Loco division Block division  Heavy Weld Shop  Heavy Machine Shop Engine division      

Engine erection shop Engine test shop Light Machine shop Sub Assembly shop Rotor shop Heat treatment shop

Loco division        

Loco frame shop Loco test shop Pipe shop Truck Machine shop Traction Assembly shop Sheet metal shop Loco paint shop Loco assembly shop

ASSIGNED AREAS   

Loco test shop (LTS) Engine Test shop (ET) Central Transport shop (CTS) Sub-assembly shop (SAS)

LOCO TEST SHOP In this shop following tests and things are checked:            

POT test Trainline continuity Blowers/fan operation Power contactor operation Dynamic break signals Engine start Engine run Excitation test Preload Load test Track test Pre-delivery test

Flow chart for loco testing-

ENGINE TEST SHOP

In this shop, testing of the engine is done for 3 hours.

Central Transport shop In transport section, there are basically two types of machine which are used for transportation purpose of the different jobs from one place to another. Different machines used are fork lift trucks  cranes

Sub Assembly Shop This shop deals with the following sections     

Turbo machining section Cylinder head and shot blast section Fuel pump, support, camshaft section Cylinder head Turbo Governor, water pump, fan drive, lube oil pump, after cooler assembly section

Cylinder head section

HearaldBoroing machine

Control Shaft Assembly

Explosion Door Cover Assembly

Cam Shaft Vibration Damper Assembly

O.S.T. Housing Assembly

Fuel Pump Support Assembly

Cylinder head fastening system

Baush Drill

Specialization of Work Culture in the Diesel Locomotive Works (DLW): In the Diesel Locomotive Works (DLW) the following specialization of work culture is followed: 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 CuttingMachine.

Components are straightened and machined prior to fitting & tacking on fixturedesigned especially for engine block fabrication to ensure close tolerance on engine block. 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 theserollovers. High quality of welding is done by qualified welders. Weld joints aresubjected 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 semi-automatic welding machines. Special fixtures are used for making downhand welding possible in inaccessible areas. Critical welds are subjected to radiographic examination. All welders are periodicallytested and re-qualified for the assigned.

After complete welding weldment is stress relieved and marking is done for subsequentmachining. Portal Milling Machine: Engine block machining is done on Portal Milling Machine which is a 5 axis CNCmachine with SIEMENs 840-D state of art system control with dedicated toolmanagement system. This machine performs milling, drilling, tapping and

boringoperations in single setting.The machine accuracy of 10”enables adhering to the tolerance required on engine block.

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 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 sizeduring angular boring. The machine is capable of boring and drilling to different sizes.

Co mpo nent ma chine: Over 2000 components are manufactured in-house at DLW. These include ALCO turbo-superchargers, lubricating oil pumps, cam shafts, cylinder heads, laser hardenedcylinder liners, connecting rods and various gears. Our wellequipped Machine Shopshave dedicated lines for operations like turning, milling, gear hobbing, drilling, grindingand planning etc.

In addition, DLW is equipped with a variety of special purpose machines and a largenumber of state-of-the-art CNC machines to ensure quality and precision.

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

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 inassembly of engine. Electrical machines like traction alternator, auxiliary generator andexiter are thereafter coupled on the engine.

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

Only after the engine parameters are found perfect the power pack are cleared for application on locomotives. Component Fabrication: Precision cutting and forming of sheet metal is utilised for manufacture of superstructures including drivers cab engine hoods, and compartments for housingelectrical equipment. All activities connected with pipes like pickling, bending, cutting,forming and threading of pipes of various sizes are undertaken in another well-equippedwork area.All electrical equipment is assembled in the fabricated control compartments anddriver's control stands are done in another work area.

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

Under frame Fabrication: Under frames are fabricated with due care to ensure designed weld strength. Requisitecamber to the under frame is provided during fabrication itself. Critical welds are testedradio-graphically.Welder training and their technical competence are periodically reviewed. High HorsePower (HHP) under frame is fabricated using heavy fixtures, positioners to ensuredown hand welding. Fixtures are used to ensure proper fitting of components andquality welding in subsequent stages.

Welder training and their technical competence are periodically reviewed. High HorsePower (HHP) under frame is fabricated using heavy fixtures, positioners to ensuredown hand welding. Fixtures are used to ensure proper fitting of components andquality welding in subsequent stages. Bogie Ma nufacturing : 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 onwheel press. The complete truck (bogie), including bogie frames, wheels and axles, brake rigging and traction motors are assembled which is ready for application tolocomotive.

Loco Assembly: Tested engines are receives from Engine Division. Similarly under frames are receivedfrom Loco frame shop and assembled trucks from Truck machine shop. Superstructurecompartments and contractor compartment are received from respective manufacturingand assembly shops of Vehicle Division. Important alignments like crank shaftdeflection, compressor alignment and Eddy Current clutch/radiator fan alignment aredone during assembly stage.

Electrical control equipments are fitted and control cable harnessing is undertaken. Thecomplete locomotive is thus assembled before being sent onwards for final testing andspray 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.

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-n arro w gaug e(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) •A-AC electric (can run under AC traction only) •CA-Both DC and AC (can run under both AC and DC tractions), 'CA' is considereda single letter •B-Battery electric locomotive (rare) 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) 5.U-Electric multiple units (used as commuters in city) 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' denotes100 HP more and so on)

Engine: There are two type of engine •EMD (Electro motive Division) •ALCO (American Locomotive) 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 andaccessories is known as accessory or governor or front end. EMD engine is known as HHP (high Horse Power) or GM (general motor). EMDengine has maximum power is 4500 HP and ALCO engine has maximum Power is3300 HP.

EMD engine

Alco engine

References      

www.indianrailways.gov.in www.dlwdesign.org https://en.wikipedia.org/wiki/Diesel_Locomotive_Works www.dlw.indianrailways.gov.in https://www.academia.edu https://www.irfca.org/