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    Diesel Locomotive Works: Varanasi

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    Gaurav Pandey
    The document summarizes Diesel Locomotive Works (DLW) in Varanasi, India. DLW was set up in 1961 in collaboration with American Locomotive Company to produce diesel locomotives for Indian Railways. It has an annual production capacity of 275 locomotives. The document describes DLW's workshops and manufacturing processes for components like engines, wheels and axles, and locomotive assembly. Key workshops include the Engine Erection Shop, Rotor Shop, Truck Machine Shop, and Loco Frame Shop. Performance of completed locomotives is tested in the Engine Testing Shop.

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    Diesel Locomotive Works: Varanasi

    Uploaded by

    Gaurav Pandey
    113 views29 pages
    The document summarizes Diesel Locomotive Works (DLW) in Varanasi, India. DLW was set up in 1961 in collaboration with American Locomotive Company to produce diesel locomotives for Indian Railways. It has an annual production capacity of 275 locomotives. The document describes DLW's workshops and manufacturing processes for components like engines, wheels and axles, and locomotive assembly. Key workshops include the Engine Erection Shop, Rotor Shop, Truck Machine Shop, and Loco Frame Shop. Performance of completed locomotives is tested in the Engine Testing Shop.

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    The document summarizes Diesel Locomotive Works (DLW) in Varanasi, India. DLW was set up in 1961 in collaboration with American Locomotive Company to produce diesel locomotives for Indian Railways. It has an annual production capacity of 275 locomotives. The document describes DLW's workshops and manufacturing processes for components like engines, wheels and axles, and locomotive assembly. Key workshops include the Engine Erection Shop, Rotor Shop, Truck Machine Shop, and Loco Frame Shop. Performance of completed locomotives is tested in the Engine Testing Shop.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    113 views29 pages

    Diesel Locomotive Works: Varanasi

    Uploaded by

    Gaurav Pandey
    The document summarizes Diesel Locomotive Works (DLW) in Varanasi, India. DLW was set up in 1961 in collaboration with American Locomotive Company to produce diesel locomotives for Indian Railways. It has an annual production capacity of 275 locomotives. The document describes DLW's workshops and manufacturing processes for components like engines, wheels and axles, and locomotive assembly. Key workshops include the Engine Erection Shop, Rotor Shop, Truck Machine Shop, and Loco Frame Shop. Performance of completed locomotives is tested in the Engine Testing Shop.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 29

    Diesel Locomotive Works

    Varanasi

    SUBMITTED BY-
    YAMIKA PATEL
    ME(B)
    Introduction
     Diesel 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 Process
    1. 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 Shop
     This 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 Shop
    Turbocharger :
    - 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 Turbocharger
     Main Casing
     Rotor Assembly
     Bearings
     Oil Seals
     Cooling System
     Lubricating System
    Truck Machine Shop
    Wheel 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 PRESSING
     Press 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 Shop
    Product basically hardened by heat treatment
    shop are –
     Cam shaft
     Push rod assembly
     Shaft valve lever
     Adjust screw crosshead
     Adjust screw valve lever
     Impeller gear
     Main piston
     Shaft
     Pin 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 Shop
    Machining process done in Loco Frame
    Shop :
     Plasma Arc Cutting
     Flame 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 Shop
    PERFORMANCE PARAMETERS :-

    1. Power and Mechanical Efficiency


    2. Fuel Air-Ratio
    3. Volumetric Efficiency
    4. Specific Output
    5. Specific Fuel Consumption
    6. Thermal Efficiency and Heat Balance
    7. Exhaust Smoke and Emissions
    8. Effective Pressure and Torque
    Fig. engine testing modals
    Fig. block structures in HWS
    THANK YOU.

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