Summer training report on diesel locomotive works Varanasi SHAILESH SHUKLA CT-1674/09MECHANICAL ENGINEERINGCAET, ETAWAH Introduction 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 dieselelectric 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 upto 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 PSUs & Industries Like NTPC, COAL, INDOGULF etc.some facts about diesel electric locomotiveDLWs annual production - 250Cost of one loco - 12 to 14 crore (EMD) 8 crore (Alco)Weight of one Loco - 121 TonFuel Consumption; At Full Load - 540 lt/hr. Idle Load - 40 lt/hr.Max. Speed - 160 Km/hr.Dia of Wheel - 1092 mmWheel to Wheel Distance - 1596.5 mm Length of Under Frame - 19962 mm Diesel electric locomotiveIn a diesel-electric locomotive, the diesel engine drives an electrical generator or alternator whose output provides power to the traction motors. There is no mechanical connection between the engine and the wheels. Classification of locomotivesLocos, except the older steam ones, have classification codes that identify them. This code is of the form WDG5A [ gauge ][ power ][load ][ series ][ sub type ] The first letter (gauge) W- Indian broad gauge Y- meter gauge Z- narrow gauge(2.5 ft) 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) B- Battery electric locomotive (rare) The third letter (load type) G-goods P-passenger M-mixed traffic ; both goods and passenger S-Used for shunting U-Electric multiple units (E.M.U.) R-Railcars THE fourth letter (series) The series digit identifies the horsepower range of the locomotive. Example for the series letter 3 means that the locomotive has power over 3000 hp but less than 4000 hp. The fifth letter (subtype) an optional letter or number that indicates some smaller variations in the basic model. For ex: A for 100 hp, B for 200 hp and so on..1. Block Divisions2. Engine Divisions3. Loco Divisions Production ShopsBlock Division1. Heavy Weld Shop2. Heavy Machine ShopEngine Division1. Engine Erection Shop2. Engine Testing Shop3. Light Machine Shop4. Sub Assembly Shop5. Rotor Shop6. Heat Treatment Shop7. Turbo SectionLoco Division1. Loco Frame Shop2. Pipe Shop3. Truck Machine Shop4. Traction Assembly Shop5. Sheet Metal Shop6. Loco Assembly Shop7. Loco Paint Shop8. Loco Test ShopWELDING shopWelding is a process which produces joining of materials by heating them to suitable temperatures with or without the application of pressure and with or without the use of filler material. Welding is used for making permanent joints. It is used in the manufacturing of automobile bodies, aircraft frames, railway wagons, machine frames, structural works, tanks, furniture, boilers, general repair work and ship building.Shielded Metal Arc Welding [SMAW]Submerged Arc Welding [SAW]Gas Shielded Metal Arc Welding [MIG]Flux Cored Arc Welding [FCAW]Types Of Welding Used In DLW**What is SMAW?It is a welding process which joins metals by heating the metals to their melting point with an electric arc set up between the end of a coated metal electrode and the work piece.Molten metal droplets and the molten weld are shielded from the atmosphere by the gases produced from the decomposition of the flux coating .2 Advantages of SMAW Equipment used is simple, inexpensive.Electrode provides and regulates its own Flux.This process has excellent suitability for outdoor use lower sensitivity to wind and even for use under water.All position capability*Build the nation with welding ***SAW Process PrinciplesSAW is a welding process which joins metals by heating the metals to their melting point with an electric arc or arcs set up between a bare metal electrode and the job. The arc, the end of electrode and molten pool remains completely hidden and are invisible being submerged under a blanket of granular flux. The continuously fed bare metal electrode melts and acts as filler rod.SAW FeaturesHigh Productivity, high amperages may be usedEasy to de-slag High QualityDeep penetrationExcellent mechanical propertiesEnvironment friendlyVery little fumeNo radiationEasy operationGMAWGas Metal Arc Welding is a welding process which joins metals by heating the metals to their melting point with an electric arc, produced between continuous consumable electrode wire and the metal being welded. Wire is fed continuously and automatically from a spool through the welding gun Shielding gases include inert gases such as argon and helium for copper and aluminum welding, and active gases such as CO2 for steel welding Bare electrode wire plus shielding gases eliminate slag on weld bead. No need for manual grinding and cleaning of slag.Applications:Used for C, Si, Cu, Ni, Ti etc.For welding tool steels and dies.For the manufacture of refrigerator parts.Gas Metal Arc ( MIG ) WeldingUses continuous wire 0.6 2.0 mm as electrodeGas shielded, inert or active gasManual, automatic or semi-automatic process High productivity If the wire feed speed is increased more current is drawn to burn it off . Increasing the current increases the arc energy and therefore the heat input. This in turn increases fusion and penetration, wire deposition rate and travel speed.FCAW Process FeaturesUses tubular wire with flux insideGas shielded (FCAW-G) or self shielded (FCAW-S)The flux produces a protective slag and/or gas coverHigh productivity process with low spatter. Smooth arc with CO2. Argon mixtures give superior performanceProblem of high fumes which need to be extracted in enclosed areas*LASER CUTTING-UPTO 4MM*UNDER WATER PLASMA CUTTING UPTO 16 MM bogie assembly shopA bogie is a wheeled wagon or trolley. In mechanics terms, a bogie is a chassis or framework carrying wheels, attached to a vehicle. Usually the train floor is at a level above the bogies, but the floor of the car may be lower between bogies.Bogie Assembly (EMD)Wheel and Axle assembly.Brake rigging assembly.Traction motor & gear case assembly.Bearing adopter assembly.Final assembly. Axle, Wheel & Axle Box assemblyThese wheels are having wear adapted profile to RDSO drawing.Dead LeverLive LeverCylinder LeverBrake ShoeBrake HeadBrake Rigging ArrangementAxle, wheel & Gear assembly with Traction Motor 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. The availability of high-powered semiconductors such asthyristors has now made practical the use of much simpler, higher-reliabilityACinduction motors.Journal bearings & adaptorThe bogie frame is supported on axles through soft primary suspension consisting of twelve single helical coil springs, two springs mounted on each bearing adapter (axle box), to provide ride quality and equalization of wheel-set loads.Bearing adapter are fitted with tapered roller pre-lubricated, pre adjusted & sealed bearings.Bearing adaptersingle helical coil springsSealed bearingsTPU shimsASSEMBLY PROCESS:PRESS BULL GEAR ON AXLE.SHIFT ABOVE ASSEMBLY AT BEARING HOUSING FITTING STAND.FIT THE BEARING HOUSING AND BOLTING .ASSEMBLE SEAL , CAP AND TAPER ROLLER BEARING BOLTING .NOW, SHIFT THIS ASSEMBLY ON WHEEL & AXLE PRESS MACHINE.Breakdown maintenance Break down of machine can occur due to the following two reasons:Due to unpredictable failure of component which cannot be prevented.Due to gradual wear and tear of the parts of the machine which can be prevented by regular inspection known as preventive maintenance. Preventive maintenance Also termed as planned maintenance or systematic maintenance .An extremely important function for the reduction of the maintenance cost and to keep the good operational condition of equipment.MAINTAINANCE AREAobjective of preventive maintenanceTo obtain maximum availability of the plant by avoiding break down and by reducing shut down period to a maximum.To keep the machine in proper condition so as to maintain the quality of the product.To ensure the safety of the workers.To keep the plant at the maximum production efficiency.To achieve the above objectives with most economical combination.MACHINE SHOPHeavy Machine ShopLight Machine Shop1. Conventional machine2. NC machine3. CNC machine1. Conventional machine: It is a simple machine which is now an old technique. 2. Numerical control machine: Numerical control is defined as a system in which the actions of the machines are controlled by the insertion of the numerical data. In other words number controls the action. Types of machines* Classification of numeric control 1. Point to point system: This feature is only useful for drilling and boring operations. The machine operations are possible at specified positions. 2. Straight line system: In this system the control can command a path operation in a single axis at a time. 3. Continuous path system: In this system the control instructs the machine to make movements like 2 or 3 axis at a time. The machine may be directed to make helical or circular path.Computerized numerically controlled machine In CNC the control system further energized with a mini computer or a post processor. The control unit stores the programmed information of the work piece, the travel limits, collisions zones and the diagnostic information etc. it also gives a feedback to the operator about the current position and distance to be travelled etc. CNC machines have the ability to edit or alter the existing program in no time. machines in area B Flame cutting CNC Laser cutting Steel plates are ultrasonically tested before being precision cut by numerically controlled flame cutting machines or by CNC LASER machine. The laser beam is typically 0.2 mm (0.008 in) diameter at the cutting surface with a power of 1000 to 2000 watts.Lasers work best on materials such as carbon steel or stainless steels because these are difficult to cut due to their ability to reflect the light as well as absorb and conduct heat. This requires lasers that are more powerful. Angular Boring MachineFabrication of Engine Block This special purpose machine has two high precision angular boring bars.Boring bars are mounted on high precision bearings which provide control on size during angular boring. 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 CNC milling machinesCNC mills can perform the functions of drilling and often turning. CNC Mills are classified according to the number ofaxesthat they possess. A standard manuallight-duty millis typically assumed to have four axes:Table x.Table y.Table z.Milling Head z. Lubricating oil testing Lubrication is done for better performance of the engine parts. testing is done by checking the circulation of lubricant oil. For rotating parts checking is done by seeing the returning path of the oil i.e. checking not only the forward path but also the returning path. RR40 is used as lubricating oil.types of testing water testingWater acts as a coolant for moving part of the engine because constant movement or rotation causes various parts to heat up and water working as coolant cooled down the concerned part. Load testing For load testing electrical load is provided to the engine. If there is any abnormal sound then the engine is again tested for lubrication so that any flaw which is there can be removed. Engine test operation sequenceBase inspection under screen and fitting over screen.Water circulation.Lube oil filling and check deflection crank shaft.Lube oil circulation.Pre run on no load 3 to 5 times of duration 10 to 30 min each 400 rpm.Intermediate runs 12 runs of 30 min duration each from 400 to 1000 rpm. Check over speed trip of recheck 3 times.Check bake in nozzles and set tapped clearance.Inspection before fist hour performance.First hour performance on full load.Base inspection.Second hour performance on full load. Attend defects of first hour performance.Final base inspection.Check engine deficiencies.Engine clearance. Transport sectionIn transport section there are basically two types of machine are used for transportation purpose of the different jobs from one shop to other.Different machines used are 1. fork lift truck 2. cranes Fork lift truck Forklift is a powered industrialtruckused to lift andtransportmaterials. Counterbalanced forklift components Truck Frame- is the base of the machine to which the mast, axles, wheels, counterweight, overhead guard and power source are attached.Cab- is the area that contains a seat for the operator along with the controlpedals,steering wheel,levers,switchesand a dashboard containing operator readouts.Overhead Guard- is a metalroofsupported by posts at each corner of the cab that helps protect the operator from any falling objects.Power Source- may consist of aninternal combustion engineor battery. cranesAcraneis a lifting machine, generally equipped with awinder,wire ropesorchainsandsheaves, that can be used both to lift and lower materials and to move them horizontally.THANKS**2***