Dlw summer training presentation

MSS, MA2, EES & SAS Shop

1. Summer Training Presentation Diesel Locomotive Works, Varanasi

2. RAJ KUMAR GOEL INSTITUTE OF TECHNOLOGY GHAZIABAD Varun Mishra 1603340194 7 th Sem Mechanical Engineering

3. Contents Introduction Facts about DLW, Varanasi Diesel Electric Locomotive Diagram Classification of Locomotives Structure of Plant MSS MA ES SAS

4. Introduction DLW was founded by Late railway minister Mr. Lal Bahadur Shastri on 23 April 1956. It is a production unit owned by Indian railways , for which it manufactures diesel–electric 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.

5. DLW rolled out its first locomotive three years later, on January 3, 1964. With technology transfer agreement from manufacturers such as GM-EMD, DLW today produces advance locomotives having output range from 2600 to 4000 hp. It has supplied locomotives to other countries such as Sri Lanka, Bangladesh, Malaysia, Tanzania and Vietnam etc. DLW is supplying locos to PSU’s & Industries Like NTPC, COAL, INDOGULF etc.

6. Facts about DLW, Varanasi During the year 2017-18, 323 locomotives were manufactured including 25 Electric locomotives and 2 locomotives converted from Diesel to Electric. During the year, two old diesel locomotives were converted to electric locomotives. It is for the first time in the world that such high horse power locomotives have been converted from Diesel to Electric. Cost of one loco - 12 to 14 crore (EMD) & 8 crore (Alco). Weight of one Loco - 121 Ton. Max. Speed - 160 Km/hr. Fuel Consumption; At Full Load - 540 lt / hr & Idle Load - 40 lt /hr.

7. Diesel Electric Locomotive Diagram In 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.

8. Classification of Locomotives Locos, except the older steam ones, have classification codes that identify them. This code is of the form- WDG5A “ [ gauge ][ power source ][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)

9. 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.) 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……..

10. Production Shop

11. Block Division

12. Engine Shop

13. Loco Division

14. Maintenance Service Shop(MSS) Maintenance, repair and overhaul involve fixing any sort of mechanical ,plumbing or electrical device that’s becomes out of order or broken. MRO may be defined as, “All actions which have the objective of restoring an item in or to a state in which it can perform its required function.” MSS is divided in these parts- Winding Shop Electronics Shop Battery Shop Meter Shop

15. A. Winding Shop- In this shop winding is done in traction motor. A traction motor is an electric motor used for propulsion of a vehicle, such as locomotives or electric roadway vehicle.

16. B. Electronics Lab- There is a full-fledged electronics lab to cater to maintenance need of highly sophisticated CNC machines and component/subassembly level trouble shooting of PCBs, Servo Drivers and Microprocessor based controllers and electronics units. This lab also supports other Zonal Railways in in repair of PCBs. Important Machines- Reverse Engineering System Automatic Test Equipment

17. B. Battery Shop- A Battery is a device consisting of two or more electro-chemical cell that converts stored chemical energy into electrical energy.

18. D. Meter Shop- Meter(in locomotive) is a device that measure’s the loco speed, air pressure, fuel, diesel pressure, power of electricity etc.

19. Maintenance Area Break 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” .

20. An extremely important function for the reduction of the maintenance cost and to keep the good operational condition of equipment. Objective of Preventive Maintenance 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

21. Engine Division Engine division is engaged in assembly and testing of 16cyl HHP diesel engine and 6cyl & 16cyl ALCO design diesel engines. Many of the vital components are manufactures in house & CNC machines installed in different shops in this division.

22. Engine Erection Shop Assembly of engine is carried out in on 4 stations in this shop. Pre inspected component like crankshaft, camshaft, oil pan etc are mounted on crankcase. During assembly all the important parameters i.e. clearance, exhaust valve setting, injector timing etc. are being maintained as per design specifications.

23. Sub-Assembly Shop There are nearly 40 shops in DLW, and SAS is a one of the important shop among them. All IC engine component of rail engine are designed here. The main purpose of this shop is to design and construct the IC engine parts of rail engine, such as piston, cylinder, crank & cam shafts etc.

24. In the designing of IC engine parts many machines are used. Some of them are- Spindle Gang Drill Machine

25. CNC Vertical Turning Lathe

26. THANK YOU