INDUSTRIAL TRAINING(PPT) DLW,Varanasi

INDUSTRIAL TRAINING IN DIESEL LOCOMOTIVE WORKS,VARANSI

1. INSTITUTE OF ENGINEERING & TECHNOLOGY Submitted By: AMIT KUMAR IV year IET, ALWAR Submitted To: Prof. AMIT MALIK HOD, Mechanical IET, ALWAR A REPORT on TRAINING(INDUSTRIAL)

2. TRAINING On DIESEL LOCOMOTIVE WORK, VARANASI (A production unit of Loco owned by I ndian Railways) From 22 May to 2 July 2015

3. INTRODUCTION DIESEL LOCOMOTIVE WORKS (DLW), Varanasi (India) an ISO 9001:14001 & OHS 18001 certified production unit owned by Indian Railways, it is a central unit of Govt. of India (ministry of Railway). It was laying of foundation stone of factory by the first president of India Late Dr. Rajendra Prasad in 1956 & Diesel Locomotive Works came existence in 1961. To meet the increased transportation needs of the Indian railways it was established in near ancient city varanasi collaboration with ALCO( American Locomotive Company), USA in 1961. First locomotive rolled out and dedicated to nation in January, 1964.

4. Got its first ISO certification in 1997 and ISO-9001 and ISO-14001 in December 2002. State of the art Design and manufacturing facility to manufacture 200 locomotive per annum with wide range of related products viz. DG Sets , Loco components and sub-assemblies. A large base of delighted customers among many countries viz. Myanmar , sri lank, Malaysia, Vietnam, Bangladesh, Tanzania, Angola, to name a few bearing testimony to product leadership in its category. At present the latest locomotive produced by DLW; i.e. WDG 5 has capacity upto 5000 HP & trying to make it 5500 HP. First loco realesed by late lal bahadur sastri in 1964 ,WDM2

5. SALIENT FEATURES : Annual production capacity 200 Locomotive Annual turn-over( Rs ) 5000 million Total number of staff 8223 Workshop land 219.997 acre Township area 520.6 acre Covered area in shops 30.37 acre Covered area of other service buildings 19.13 acre Water consumption 223.82 Lakh Litres /day Electrical Energy Consumption 262.07 Lakh Unit / Year Workshop 4200 KVA Administrative Building 1500 KW Stand by Power Generation Capacity 5625 KW

6. some facts about diesel electric locomotive DLW’s annual production -250 Cost of one loco - 12 to 14 crore (EMD) 8 crore (Alco) Weight of one Loco - 121 Ton Fuel Consumption; At Full Load - 540 lt /hr. Idle Load - 40 lt /hr. Max. Speed - 160 Km/hr. Running speed on track -110-20 km/ hr Dia of Wheel - 1092 mm(OD) Wheel to Wheel Distance - 1596.5 mm Length of Under Frame - 19962 mm

7. Integrated Quality, Environment, Health and Safety Policy:

8. Product of DLW: 1.WDG5 5500 HP AC/AC Freight operation type locomotive 2. WDG4 4000 HP AC/AC Freight Traffic Locomotive 3. WDP4 4000 HPAC/AC Broad Gauge High Speed 4. WDG3D 3400 HP AC/AC Broad Gauge Mixed Traffic Micro-Processor Controlled Locomotive. 5. WDP3A 3100 HP AC/DC Broad Gauge High Speed passenger Locomotive 6. WDM2 2600 HP AC/DC Broad Gauge Mixed Traffic Locomotive 7. YDM4 1350 HP AC/DC &DC/DC Broad Gauge Mixed Locomotive 8. WDP4D 4400 HP ac/ac Broad Gauge High Speed Locomotive

9. General information about some locomotive product (WDG4): Installed  Power 4000HP   Axle Load 21T   Gauge 1676mm   Wheel arrangement Co-Co Wheel diameter 1092mm Height 4201mm Width 3137mm Overall Length (Over Buffer Beam) 19964m Weight 126T Max tractive effort 54T Maximum speed 100kmph Fuel tank capacity 6000lts Locomotive Control EM 2000 with SIBAS­16 Traction Control Gear Ratio  90:17

10. Besides the Indian Railway, it regularly exports diesel electric locomotive and has supplied locomotives to other countries such as Sri Lanka, Malaysia, Bangladesh, Mali, Senegal, Sudan, Tanzania, Angola, Mozambique and Vietnam and also to a few users within India, such as ports, large power and steel plants and private railways. List of locomotive supplied to Non Railway Customers; 1. SAIL 2. VSP 3. NTPC 4. SEB & OTHERS MRAKETING STATERGY:-

11. Diesel electric locomotive 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.

12. In India, locomotives are classified according to their track gauge, motive power, the work they are suited for and their power or model number. The class name includes this information about the locomotive.it comprises 4 and 5 letters . Classification of locomotives Classification of locos on the basis of code form WDG5A “ [ gauge ][ power ][load ][ series ][ sub type ]” In the first letter [Gauge]: W-Indian Broad Gauge (5.6ft) Y-Meter Gauge or Yard Gauge (the "Y" stands 3ft or 1000mm) Z-Narrow Gauge (2.5ft) N-Narrow Gauge or Toy Gauge (2ft)

13. In the second letter [Power]: D-Diesel C-DC Traction (can run under DC traction only) A-AC Traction (can run under AC traction only) CA-Both DC and AC (can run under both AC and DC tractions) B-Battery Electric Motive (rare) In the third letter [Load]: G-goods P-passenger M-mixed Traffic (both goods and passenger) S-Used for Shunting U-Electric multiple units (EMU) R-Railcars

14. In 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 3000hp but less than 4000hp. In the fifth letter [subtype]: An optional letter or number that indicates some smaller variations in the basic model. For ex: ‘A’ for 100hp, ‘B’ for 200hp and so on…….. Example: Designation of ‘WDM-3A’ mean "W" means broad gauge "D" means diesel motive power "M" means suitable for both goods and passenger service "3A" means the locomotive's power is 3,100 hp ('3'stands for 3000hp ’’A' denotes 100hp more)

15. WDG5 Preliminary Locomotive Layout:

16. Specification: Fuel tank capacity - 7500lts Weight - 133.8ton Length - 22.3m Wheel arrangement - co-co Gear ratio - 90:21

17. Production Shops

18. BLOCK DIVISION: i. Heavy Weld Shop ii. Heavy Machine Shop Engine Divisions: i. Light Machine Shop ii. Engine Erection Shop iii. Engine Testing Shop iv. Sub Assembly Shop v. Rotor Shop vi. Heat Treatment Shop Loco Divisions: i. Loco Frame Shop ii. Pipe Shop iii. Truck Machine Shop iv. Sheet Metal Shop v. Traction Assembly Shop vi. Loco Assembly Shop vii. Loco Test Shop viii. Loco Paint Shop

19. Production Flow Chart :

20. CHEMICAL & METALLURGICAL TESTING LAB Chemical & Metallurgical Testing is domain of material science and engineering that studies the physical and chemical behaviour of metallic elements, and their intermetallic compounds and their mixture before used in manufacturing process define/calculate its various properties via testing for good quality & safety purpose. In DLW, Testing Lab is divided in various section like that chemical, physical, metallography section etc . Basic Properties of metal : i . Physical properties ii. Mechanical properties iii. Chemical properties iv. And properties like Thermal, Electrical, Magnetic

21. ENGINE ERACTION SHOP Engine eraction shop (EES) is part of Engine Division. In EES, Eraction means built engine with assembly different-different items of engine, In these under shop deals with different items parts assembly and different items of engine. In under shop two types Engine eracted ; ALCO 2. GM

22. DEBURRING, WASHING & PAINT SECTION PISTON CRANK SHAFT & CYLINDER ERACTION PISTON CRANK SHAFT & CYLINDER HEAD ERACTION GENERATOR CAMSHAFT CONTROL SHAFT & APPLICATION FUEL PUMP & VALVE LEVERS

23. ERACTION SHOP OF GM

24. PRODUCTION PLANNING AND CONTROL OFFICE Production control is the task of predicting, planning and scheduling work, taking into Account manpower, material availability and other capacity restrictions, and cost so as to achieve proper quality and quantity at time it is needed and then following up the schedule to see that the plan is carried out, using whatever systems have proven satisfactory for the purpose. Production And Planning Control Function:- i . Planning ii. Routing iii. Loading iv. Scheduling v. Combing Function vi. Dispatching vii. Reporting or Follow –up. viii. Corrective Action ix. Inspection

25. MAINTENANCE AREA Maintenance is the action associated with equipment repair after it is broken. Also maintenance as follows” the work of keeping something in proper condition ;upkeep.” This would imply that maintenance should be action taken to prevent a device or component from failing or to repair normal equipment degradation experienced with the operation of the device to keep it in proper working order. In DLW maintenance area divided into two section based on machine works as LMS & HMS . TYPES OF MAINTENANCE: It is basically; i . Breakdown Maintenance ii. Preventive Maintenance Breakdown Maintenance: Breakdown maintenance is maintenance performed on equipment that has broken down. Breakdown maintenance may be either planned or it can be unplanned. Break down of machine can occur due to the following two reasons: a. Due to unpredictable failure of component which cannot be prevented. b. Due to gradual wear and tear of the parts of the machine which can be prevented by regular inspection known as preventive maintenance.

26. Preventive maintenance : Preventive maintenance (PM) is a fundamental, planned maintenance activity designed to improve equipment life and avoid any unplanned maintenance activity . 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. objective of preventive maintenance 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.

27. SUB ASSEMBELY SHOP (SAS/EES) Wheel and Axle assembly Brake rigging assembly Traction motor & gear case assembly

28. Axle , wheel & Gear assembly with Traction Motor

29. LOCO PAINT SHOP After the Loco (engine) is made they are sent for final work of painting. Loco painting is done by spray paint. Skilled workers are employed who can make markings take shape and size under consideration. Fig. spray paint gun

30. In DLW, Loco Paint Shop is divided into different- different section, which under section different -different portion painted for a specified colours. BODERING: Light Buiscuite , Deep Yellow colour are used for WDG4. And Dazziling white, Golden yellow colour are used for WDP4. FINISHING: Pickock Blue Colour are used for WDG4. And French Blue colour are used for WDP4 . FOR TRUCK PORTION: Black paint used in both WDG4 & WDP4 . In DLW, Two types paint are used:- 1 . Enamel Paint 2. Polyvinyle Paint For safety purpose from dust particle used glass, rubber, builder plates,cables . And resist from dust particle, Loco is spry by EZP (EPOXY ZINC PHOSPHATE). Epoxy Surfacer :- It is a process in paint (epoxy paint) is used for fill up all the gaps properly.

31. Fig. paint shop

32. EXPORTED LOCOMOTIVE:- In DLW, Figures of some standard locomotive which is exported out of country,