Diesel Locomotive WorksVaranasi

SUBMITTED BY- YAMIKA PATELME(B)

IntroductionDiesel Locomotive Works (DLW) is

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.

This unit produces diesel electronic locomotives and DG sets for Indian railways and other customers in India and Abroad.

Salient Features:

- Annual production capacity 275 Locomotives - Annual turn-over (Rs) 5000 million- Total number of staff 7223- Workshop land 89 Hectares - Township area 211 Hectares - Electrical power requirement 3468 KVA (Average maximum demand)- Electrical energy consumption 19.8 million (units/year)- Stand by power generation capacity 3000 KW

What I Learned ??Engine Nomenclature :- What does Engine name WDM 3A

signifies ?

The first letter describes (gauge) • W- broad gauge • Y- meter gauge • Z- narrow gauge(2.5 ft) • N- narrow gauge (2 ft)

The second letter describes (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 considered a single letter • B - Battery electric locomotive (rare)

The third letter describes (job type) • G - goods • P - passenger • M- mixed; both goods and passenger • S - Used for shunting (Also known as switching engines or switchers in United states and some other countries) • U - Electric multiple units (used as commuters in city suburbs) • R - Railcars

The Fourth Number describes Horse Power in 1000’s

The fifth letter describes additional HP in 100’s

Therefore WDM3A signifies• "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)

Manufacturing Process1. ENGINE DIVISION

- Component Machining- Engine Testing and Machining

2. BLOCK DIVISION- Flame Cutting of Components- Fabrication of Engine Block/Crankcase

- Portal Milling Machine- Angular Boring Machine

3. LOCO DIVISION -Component Fabrication -Under Frame Fabrication -Bogie Manufacturing -Locomotive Assembly

Workshops- Engine Erection Shop (EES)- Rotor Shop (RS)- Truck Machine Shop (TMS)- Heat Treatment Shop (HTS)- Sub Assembly Shop (SAS)- Loco Frame Shop (LFS)- Engine Testing Shop (ETS)- Heavy Weld Shop (HWS)

Engine Erection ShopThis shop deal with different sub assembly and

different items of engine. There are seven sections.

-Paint Section -Piston Crank Shaft & Cylinder Erection-Piston Crank Shaft & Cylinder Head Erection-Generator Cam Shaft Control Shaft & Turbo

Application.- Engine Testing-Fuel Pump -Piping & Miscellaneous

Rotor ShopTurbocharger :- The turbocharger is a unit, composed of a gas turbine and a centrifugal blower,

mounted a common shaft.- The exhaust gas from cylinders of the diesel

engine is conveyed through the exhaust manifold to the turbine, which utilizes the velocity and heat energy in the exhaust gas.

- This energy is used to drive the blower, which furnishes all the air required by the engine, through the air intake manifold at a pressure atmospheric..

Construction of TurbochargerMain CasingRotor AssemblyBearingsOil SealsCooling SystemLubricating System

Truck Machine ShopWheel and Axle Assembly -

Main parts of wheel and axle assembly:

Axle

Wheel Bull Gear

Seal Seal Cap

Bearing Housing Spacer

Taper Roller Bearing Ring

Wheel Pressing Machine

ASSEMBLY PROCESS:- Press Bull gear on axle.- Shift above assembly at bearing housing fitting Stand.- Assemble Seal , Cap and Taper Roller Bearing (at Power End Side).- Fit the bearing housing and bolting (70-100lbs).- Assemble Seal , Cap and Taper Roller Bearing (Free End Side).- Bolting (70-100lbs).- Now, shift this assembly on Wheel & axle press machine.

WHEEL PRESSINGPress 1st wheel at free end maintaining

continuous pressure at 80- 130 Torr.Press 2nd wheel at power end maintaining

continuous pressure at 80 – 130Torr.Maintain the wheel to wheel distance

1596 mm. ( ± 0.5 mm).Press journal bearing at both side of the

axle. ( at 50 Torr pressure).Bolt up bearing and cap with axle. ( torque pressure : 420 lbs).Assembly completed.

Assembled Wheel and Axle

Heat Treatment ShopProduct basically hardened by heat

treatmentshop are –Cam shaftPush rod assemblyShaft valve leverAdjust screw crossheadAdjust screw valve leverImpeller gearMain pistonShaftPin cam roller

Heat Treatment:

• The hardening temperature is about 780 ºC.

• Steels are oil quenched.

• When the surface temperature of the steel has fallen to between 400 ºC and 300 ºC the water quenching is interrupted by transferring the tool to an oil bath.

Loco Frame ShopMachining process done in Loco FrameShop :Plasma Arc CuttingFlame Cutting

Cutting Process (i) Oxy acetylene flame preheat the metal to the ignition point at the place to be cut. It also provides a protective shield between the cutting oxygen stream and the atmosphere. 

(ii) Cutting oxygen combines with iron to form iron oxide.(iii)Cutting oxygen jet blows away molten iron and iron

oxide thereby cutting a narrow slit or kerfs in the metal object.Cutting temperature 3100-3200 degree Celsius.

Engine Testing ShopPERFORMANCE PARAMETERS :- 1. Power and Mechanical Efficiency2. Fuel Air-Ratio3. Volumetric Efficiency4. Specific Output5. Specific Fuel Consumption6. Thermal Efficiency and Heat Balance7. Exhaust Smoke and Emissions8. Effective Pressure and Torque

Fig. engine testing modals

Fig. block structures in HWS

THANK YOU.