Indian Railways Diesel Locomotive Works: Technical Training Crntre
Indian Railways Diesel Locomotive Works: Technical Training Crntre
Indian Railways Diesel Locomotive Works: Technical Training Crntre
INDIAN RAILWAYS
TECHNICAL TRAINING CRNTRE
DIESEL LOCOMOTIVE WORKS
Varanasi 221004
GAUTAM BUDHA TECHNICAL UNIVERSITY, LUCKNOW, INDIA
2011-12
BACHELOR OF TECHNOLOGY
degree
In
MECHANICAL ENGINEERING
submitted
by
AMIT KUMAR CHAUHAN
to
Mr. Y.S.RAJPUT
(LECTURERE OF DEPARTMENT)
COLLEGE OF ENGINEERING
&
RURAL TECHNOLOGY
MEERUT
TABLE OF CONTENTS
1. Acknowledgment
2. Preface
3. Introduction
4. Brief History
5. Product
EMD
WDP4
6. Manufacturing Process
Engine Division
Vehicle Division
Block Devision
7. Workshops
LMS
ET
TMS
LAS
8. Orginizational Strength
9. Our Quality Policy
10. Environmental/ Societal Orientation
ACKNOWLEDGEMENT
I owe a great many thanks to a great many people who helped and
supported me during making of this reporte.
Founded in 1961, the DLW rolled out its first locomotive three
years later, on January 3, 1964. It manufactures locomotives which are
variants based on the original ALCO designs dating to 1960s and
the GM EMD designs of the 1990s. DLW has an annual production
capacity of 150 locomotives and plans to increase it to 200 based on the
current demand.
Varanasi, one of the oldest populated cities in the world and has a
promising place in the international ground both as a hub of traditions
and technology. One side the humming of divine and holy bells of the
temples brings the city to life; on other side Diesel Locomotive Works
(DLW) Varanasi is one of the largest industrial unit in eastern part of the
nation. DLW catch the attention of lot of foreign tourist students to
observer on going amazing locomotive manufacturing process in
Varanasi. Diesel Locomotive works Varanasi is located at the North end
of the city and about 8 Km away from the Holy River Ganges Ghats.
DLW is an ISO 9002, ISO 14001 & OHS 18001 Certified Organisation .
August 1961 DLW set up as a green field project in technical collaboration with ALCO, USA for
manufacture of Diesel Electric Locomotives
January 1964 First Locomotive rolled out and dedicated to the Nation
January 1976 Entered Export market, first locomotive exported to Tanzania
December 1977 First Diesel Generating Set commissioned
October 1995 The Transfer of Technology agreement was signed
March 2002 The first indigenous EMD WDG4 freight loco manufactured
November 2002 3600 HP Engine produced
March 2003 The first indigenous passenger version of EMD loco WDP4 manufactured
September 2003 Development of 16 cylinder 3300 HP Power upgraded DLW engine, WDM3D locomotive
2006 5000th locomotive produced
November 2006 DLW manufactured first WDG4 locomotive equipped with IGBT based converter
March 2007 First WDP4 locomotive equipped with IGBT based converter
DLW has successfully switched over to use of microprocessor based control system on all its
April 2007
locomotives.
March 2009 257 locomotives manufactured in 2008-09, highest ever locomotive production
November 2009 5690 locomotives upto 30th Nov’2009(including 348 EMD locos)
PRODUCT
EMD
WDG4 - 4000 HP GOODS LOCOMOTIVE
Truck Brakes
High adhesion Electronic Air Brake
HTSC ( High Tensile Steel Cast) System ( KNORR-NYAB-
truck of bogie Computer Controlled Braking)
Axle Load 21 T
Gauge 1676 mm
Height 4201 mm
Width 3127 mm
WDP4
4000 HP PASSENGER LOCOMOTIVE
Truck Brakes
High adhesion HTSC ( Electronic Air Brake
High Tensile Steel Cast) truck or bogie System ( KNORR-NYAB-Computer
Gauge 1676 mm
Height 4201mm
Width 3127 mm
TECHNICAL INFORMATION
Wheel Co – Co
Arrangement
Weight 72 t
Overall 15600 mm
Length
Wheel 921 mm
Diameter
Maximum 90 Kmph
Speed
Diesel Engine Type : ALCO 251 D 6
Cyl. in line.
HP 1350
TECHNICAL INFORMATION
Wheel Co-Co
Arrangement
Weight 102 t
Gear Ratio 18 : 93
HP 2300
Train Air
TECHNICAL INFORMATION
Wheel Co-Co
Arrangement
Weight 102 t
Overall 17620 mm
Length
Wheel 921 mm
Diameter
Gear Ratio 18 : 93
HP 2300
Brake IRAB-1
Train Air
TECHNICAL INFORMATION
( Provisional Specifications)
Wheel Co-Co
Arrangement
Weight 114 t
Overall 18632 mm
Length
Wheel 1000 mm
Diameter
Gear Ratio 19 : 92
HP 3000
Brake IRAB-1
Train Air
TECHNICAL INFORMATION
Weight 72 t
Overall 15600 mm
Length
Wheel 965 mm
Diameter
Maximum 96 Kmph
Speed
HP 1350
TECHNICAL INFORMATION
Wheel Co-Co
Arrangement
Weight 123 t
Gear Ratio 18 : 74
HP 3100
Brake IRAB-1
Train Air
TECHNICAL INFORMATION
Wheel Co-Co
Arrangement
Weight 117 t
Wheel 1092 mm
Diameter
Gear Ratio 18 : 65
Transmission Electric AC / DC
Train Air
TECHNICAL INFORMATION
Wheel Co-Co
Arrangement
Weight 113 t
Wheel 1092 mm
Diameter
Gear Ratio 74 : 18
Maximum 50 Kmph
Speed
Diesel Engine Type : 251 D-6 Cyl. in-line
MANUFACTURING PROCESS
Engine Division
COMPONENT MACHINING
Only after the engine parameters are found perfect the power
packs are cleared for application on locomotives.
Vehicle Division
Component Fabrication
Precision cutting and forming of sheet metal
is utilised for manufacture of superstructures
including drivers cab, engine hoods, and
compartments for housing electrical
equipment. All activities connected with
pipes like pickling, bending, cutting,
forming and threading of pipes of various
sizes are undertaken in another well-equipped work area.
All electrical equipment is assembled in the fabricated control
compartments and driver?s control stands is done in another work
area.
BOGIE MANUFACTURING
Special purpose machines are utilised for
machining cast and fabricated bogie frames.
Axle and wheel disc machining is
undertaken on sophisticated CNC machines.
Inner diameter of wheel discs are matched with the outer diameter
of axles and assembled on wheel press. The complete truck
(bogie), including bogie frames, wheels and axles, brake rigging
and traction motors are assembled which is ready for application
to locomotive.
LOCOMOTIVE ASSEMBLY
Tested engines are received from Engine
Division. Similarly under-frames are received
from Loco frame Shop and Assembled trucks
from Truck Machine Shop. Superstructures and
contractor compartments are received from
respective manufacturing and assembly shops of Vehicle Division.
Important alignments like crank shaft deflection, compressor
alignment and Eddy Current clutch/radiator fan alignment are done
during assembly stage.
Electrical control equipments are fitted and control cable harnessing is
undertaken. The complete locomotive is thus assembled before being
sent onwards for final testing and painting.
all locomotive systems are rigorous tested as per laid down test
procedures before the locomotive is taken up for final painting and
dispatch.
Block Division
This shop deals with the matching of vario us small co mpo nents
required fo r the power pack unit such as, cam shaft, co nnecting rod,
liners, gears levers, F.P. Support, Piston pin, nuts and bo lts bushes,
various shafts etc.
We shall:
Set objectives & targets and periodically monitor
their progress through internal audit and
management review.
Communicate Quality, Environment and Health &
Safety policy to the employees and to make it
available to the public on demand.
Environmental/Societal Orientation
Environmental Management
A healthy and congenial environment alone can produce and promote
healthy citizens we firmly believe. In order to have a clean and green
DLW, we have a well defined integrated environmental policy. This
promotes an ever motivated work-force, giving rise to products of
International standard.
Environmental Objectives:
Reduction in Resourceconsumption
Reduction in Fire Emergencies -10%
every year
Improvement in Emergency
preparedness
Monitoring of water & ambient air periodically
Sewage Treatment Plant:
STP is mainly concerned with the treatment of domestic and industrial
sewage. The treated water is used for irrigation
purpose up to nearby Lohta farm and kitchen
gardening at DLW premises.The digested sludge
is sent to sludge drying beds, later to be used as
manure. Methane gas mainly produced from the
digester is collected in the gas holder and supplied to the canteen.
OHS Objectives:
Reduction in HOD cases -10% every year
Improvement in use of PPEs (100%)
Recharging of Ground water