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    Diesel Locomotive Work Varanasi: Presented By: Shadab Alam

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    Hope Them
    The document provides information about Diesel Locomotive Works (DLW) in Varanasi, India. DLW produces diesel-electric locomotives and diesel generators for Indian Railways and international customers. It was established in 1961 in collaboration with American Locomotive Company. DLW now manufactures locomotives using both ALCO and General Motors technologies, making it the only plant in the world with both. Facilities include shops for heavy welding, machine work, engine assembly, testing and more. Products include various types of locomotives up to 4000 horsepower. The document describes the rotor shop production of turbochargers, a key engine component. It also outlines the heat treatment processes used.

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    Diesel Locomotive Work Varanasi: Presented By: Shadab Alam

    Uploaded by

    Hope Them
    25 views15 pages
    The document provides information about Diesel Locomotive Works (DLW) in Varanasi, India. DLW produces diesel-electric locomotives and diesel generators for Indian Railways and international customers. It was established in 1961 in collaboration with American Locomotive Company. DLW now manufactures locomotives using both ALCO and General Motors technologies, making it the only plant in the world with both. Facilities include shops for heavy welding, machine work, engine assembly, testing and more. Products include various types of locomotives up to 4000 horsepower. The document describes the rotor shop production of turbochargers, a key engine component. It also outlines the heat treatment processes used.

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    summer internship report

    Original Title

    DLW Harikesh

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    The document provides information about Diesel Locomotive Works (DLW) in Varanasi, India. DLW produces diesel-electric locomotives and diesel generators for Indian Railways and international customers. It was established in 1961 in collaboration with American Locomotive Company. DLW now manufactures locomotives using both ALCO and General Motors technologies, making it the only plant in the world with both. Facilities include shops for heavy welding, machine work, engine assembly, testing and more. Products include various types of locomotives up to 4000 horsepower. The document describes the rotor shop production of turbochargers, a key engine component. It also outlines the heat treatment processes used.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    25 views15 pages

    Diesel Locomotive Work Varanasi: Presented By: Shadab Alam

    Uploaded by

    Hope Them
    The document provides information about Diesel Locomotive Works (DLW) in Varanasi, India. DLW produces diesel-electric locomotives and diesel generators for Indian Railways and international customers. It was established in 1961 in collaboration with American Locomotive Company. DLW now manufactures locomotives using both ALCO and General Motors technologies, making it the only plant in the world with both. Facilities include shops for heavy welding, machine work, engine assembly, testing and more. Products include various types of locomotives up to 4000 horsepower. The document describes the rotor shop production of turbochargers, a key engine component. It also outlines the heat treatment processes used.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 15

    DIESEL LOCOMOTIVE WORK

    VARANASI

    Presented by:
    SHADAB ALAM
    INTRODUCTION
    Background
     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.
     Subsequently a contract for transfer of technology of 4000 HP

    Microprocessor Controlled AC/AC Freight (GT 46 MAC) /


    passenger (GT 46 PAC) locomotives and family of 710 engines
    has been signed with electro motive division of general
    motors of USA for manufacture in DLW. the production of
    these locomotives has now started and thus DLW is the only
    manufacturers of Diesel Electric Locomotives with both ALCO
    and General motors technologies in the world.
    PRODUCT OF DLW
     DLW is an integrated plant and its
    manufacturing facilities are flexible in nature.
    these can be utilized for manufacture of
    different design of locomotives of various
    gauges suiting customer requirements and
    other products. the product range available is
    as under. :
     WDG4 4000 HP AC/AC Freight traffic Locomotive
     WDP4 4000 HPAC/AC Broad Gauge High Speed Locomotive
     WDG3D 3400 HP AC/AC Broad Gauge Mixed Traffic Micro-Processor

    controlled Locomotive.
     WDM3C 3300 HP AC/DC Broad Gauge Mixed Traffic Locomotive.
     WDM3A 3100 HP AC/DC Broad Gauge Mixed Traffic Locomotive.
     WDP3A 3100 HP AC/DC Broad Gauge High Speed Passenger Locomotive.
     WDG3A 3100 HP AC/DC Broad Gauge Freight Locomotive.
     WDM2 2600 HP AC/DC Broad Gauge Mixed Traffic Locomotive.
     WDP1 2300 HP AC/DC Broad Gauge Intercity Express Locomotive.
     WDM7 2150 HP DC/DC Broad Gauge Mixed Traffic Locomotive.
     WDM6 1350 HP DC/DC Broad Gauge Mixed Traffic Locomotive.
     WDS6 1350 HP AC/DC & DC/DC Broad Gauge Shunting Locomotive.
     YDM4 1350 HP AC/DC & DC/DC Broad Gauge Mixed traffic Locomotive.
     EXPORT LOCO 2300 HP AC/DC Meter Gauge/Cape gauge Mixed Traffic Locomotive.
     Diesel Generating Sets 800 KW to 2500 KW
     Spare Parts for engines, locomotives and generating sets
    Production Shops
     Production shops are divided in three divisions-
    1.Block Divisions
    2. Engine Divisions
    3. Loco Divisions
     Block Division

    1. Heavy Weld Shop


    2. Heavy Machine Shop
     Engine Division

    1. Engine Erection Shop


    2. Engine Testing Shop
    3. Light Machine Shop
    4. Sub Assly. Shop
    5.Rotar Shop
    6. Heat Treatment Shop
     Loco Division
    1. Loco Frame Shop
    2. Pipe Shop
    3. Truck Machine Shop
    4. Traction Assly. Shop
    5. Sheet Metal Shop
    6.Loco Assly. Shop
    7. Loco Paint Shop
    8. Loco Test Shop
     Service Shops

    1. Maintenance Areas 1, 2, 3
    2. Tool Room
    3. Central Transport Shop
    HEAVY MACHINE SHOP
     SHOP No. – 04
     This shop carries out the machining of Cyl. BLOCK (M.G. & B.G.)
    main base, saddler Main bearing caps, Splines, Turbo Super
    Charger, Lube Oil, Fuel Oil & Water header) com bearing housing.
    OPERATION:-
     Planning, Milling, Drilling, Tapping, Boring Honing, Serration

    milling etc.
     Types of Machine provided in the shop are :-

     Double Housing planned machine (32”, 24’, & 16’).

     Radial drilling machine.

     Radial drilling machine Traveling type.

     Boring Machine

     Angular Boring Machine (Excello)

     Tracer Planner machine.

     Hill Acme koing structural milling machine.


    ROTOR SHOP
     This shop is deals with the manufacturing of
    Turbocharger. Turbocharger is known as the Heart of
    Diesel Locomotive. Basically in this
    section manufacturing of assembly & sub assembly of T
    urbocharger is made. But the outer casing of
    Turbocharger is made up in Heavy Machine Shop
     Turbocharger is use for the providing fresh air to the
    engine. Due to
    this the efficiency & power generated by engine is increa
    sed. For the running of Turbocharger we are not using
    any extra energy source like generator, motor etc. For
    starting of Turbocharger generally we use exhaust
    gasses.
    Components of Turbocharger:--
     For assembly of Turbojet following parts are manufactures in

    rotor shop----
    1.Impeller 2.Inducer 3.Nose piece4.Stud Rotor 5.Nut6.Washer 7.Thrust Was
    her 8.Key9.Oil Slinger 10. Turbine Disc11.Turbo Shaft12. Lock plate
    Assembly of Turbocharger :-- 
     The assembly of turbocharger is done by dividing wholeturbocharger in

    three parts. These are as follows----1.Rotor 2.Compressor 3.Casing


    1. Rotor:--   
     Rotor is the inlet part of turbocharger which is comprises with following

    parts. Turbo Disc, Rotor stud, Turbo shaft, thrust collar, Nose disc, Washer
    & Nut Rotor is rotating at speed of 18000 rpm & working at high
    temperature due to that the rotor is made of steel.
    2. Compressor:--
     Compressor is the combination of impeller & inducer. Impeller is made up

    of Al-alloy. Impeller & inducer is use for sucking of fresh air from


    environment.
    3.Casing:--
     Casing is made of M.S. & also a special type of coating is done. Due to that

    coating it can easily resist the heat. For the proper working & life of
    Turbocharger balancing of impeller, inducer & turbine disc is done by help
    of Dynamics Balancing Machine
    SALIENT FEATURE OF G.M. MOTOR
    TURBOCHARGER
    No. per engine—1 
    2. Stages—Single stage 
    3. Drive—Mechanical drive as well as exhaust gas driven with over
    running clutch. 
    4. Air Flow—6.35kg/s(Rated O/P)
    5. Efficiency (At match pt.)--
     Turbine—87.2%
     Compressor—81.5%
     Mechanical—87.8% 
    6. Temperature for which critical components are designed— 
     • Compressor Stage— --Air temperature up to 190.6°C
     • Turbine stage----Gas temperature up to 593.3°C--Gas
    temperature up to 482.2°C on outlet side. 
    7. Pressure Ratio of Compressor –2.8 
    8. Temp. (Charge air after compressor)-- 171°C 
    9. Speed of Turbo (At rated O/P)—18,950rpm
    HEAT TREATMENT SHOP
    In this shop hardening, stress leaving, temper
    ing, normalizing, carburizing,  quenching,  is 
    done by help of conventional &unconventiona
    l process. Here we are doing hardening of ca
    m-shaft, connecting rod, piston pin, different
    small components of cylinder head. This shop
    is divided in two parts which are as follows— 
    1.Induction Section—Use for Induction
    hardening
    2.Furnace Section—Use for Overall process
    Engine Testing

    WLB
    FPM
    Control WLB
    Panel
    Governor

    ACB

    TA Engine sensors

    Monitor

    Indications

    Ex.
    Console Panel

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