REPORT ON SUMMER TRAINING AT DLW, VARANASI

By: Himanshu Singh

MIE 7th semester

Dronacharaya college of engg.

INDIAN RAILWAYS: AT A GLANCE

Indian Railways (Hindi: भा�रती�य र�ल Bhāratīya Rail), abbreviated as IR (Hindi: भा�.र�.), is a departmental undertaking of Government of India, which owns and operates most of India's rail transport. It is overseen by the Ministry of Railways of the Government of India.

Indian Railways has 113,617 kilometres (70,598 mi). of total track over a route of 63,974 kilometres (39,752 mi) and 7,083 stations. It has the world's fourth largest railway network after those of the USA , Russia and China. The railways traverse the length and breadth of the country and carry over 30 million passengers and 2.8 million tons of freight daily . It is the world's second largest commercial or utility employer, with more than 1.36 million employees  As for rolling stock, IR owns over 219,931 (freight) wagons, 51,030 coaches and 8,889 locomotives.

PRODUCTION UNITS

Indian Railways manufactures much of its rolling stock and heavy engineering components at its six manufacturing plants, called Production Units, which are managed directly by the Ministry. Popular rolling stock builders such as CLW and DLW for electric and diesel locomotives; ICF and RCF for passenger coaches are Production Units of Indian Railways. Over the years, Indian Railways has not only achieved self-sufficiency in production of rolling stock in the country but also exported rolling stock to other countries. Each of these six production units is headed by a General Manager, who also reports directly to the Railway Board. The six Production Units are:-

Sl. No Name Abbr.Year

EstablishedLocation

Main products

1.Chittaranjan Locomotive Works

CLW 1947 ChittaranjanElectric Locomotives

2.Diesel Locomotive Works

DLW 1961 VaranasiDiesel-electric Locomotives

3.Diesel-Loco Modernisation Works

DLW 1981 PatialaDiesel-electric Locomotives

4.Integral Coach Factory

ICF 1952 ChennaiPassenger coaches

5.Integral Coach Factory

RCF 1986 KapurthalaPassenger coaches

6.Rail Wheel Factory

RWF 1984 BangaloreRailway wheels and axles

DIESEL LOCOMOTIVE WORKS, VARANASI

Brief historyAugust 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

March2003

The first indigenous passenger version of EMD loco WDP4 manufactured

September 2003Development of 16 cylinder 3300 HP Power upgraded DLW engine, WDM3D  locomotive

2006   5000th locomotive produced

November 2006DLW manufactured first WDG4 locomotive equipped with IGBT based converter

March 2007 First WDP4 locomotive equipped with IGBT based converter

April 2007DLW has successfully switched over to use of microprocessor based control system on all its locomotives.

March 2009257 locomotives manufactured in 2008-09, highest ever locomotive production

November 20095690 locomotives upto 30th Nov'2009(including 348 EMD locos)

ORGANIZATIONAL STRENGTH

A flagship production unit of Indian Railways offering complete range of products in its area of operation with annual turnover of over 2124 Crore. 

State of the art Design and Manufacturing facility to manufacture 200 locomotives per annum with wide range of related products viz. DG Sets, Loco components and sub-assemblies. 

Supply of spares required to maintain Diesel Locomotives and DG sets. 

Unbeatable trail-blazing track record in providing cost-effective, eco-friendly and reliable solutions to ever increasing transportation needs for over four decades. 

Fully geared to meet specific transportation needs by putting Price - Value - Technology equation perfectly right. 

A large base of delighted customers among many countries viz. Myanmar, Sri Lanka, Malaysia, Vietnam, Bangladesh, Tanzania, Angola, to name a few, bearing testimony to product leadership in its category.

TYPES OF LOCOMOTIVES PRODUCED AT DLW

The first letter (gauge)1. W-Indian broad gauge (The "W" Stands for Wide

Gauge - 5 Feet)2. Y-metre gauge (The "Y" stands for Yard Gauge - 3

Feet)3. Z-narrow gauge(2 ft 6 in)4. N-narrow gauge (2 ft) The second letter (motive power)1. D-Diesel2. C-DC electric (can run under DC traction only)3. A-AC electric (can run under AC traction only)4. CA-Both DC and AC (can run under both AC and DC

tractions), 'CA' is considered a single letter5. B-Battery electric locomotive (rare)

The third letter (job type)

1. G-goods

2. P-passenger

3. M-mixed; both goods and passenger

4. S-Used for shunting (Also known as switching engines or switchers in United states and some other countries)

5. U-Electric multiple units (used as commuters in city suburbs)

6. R-Railcars

For example, in "WDM 3A":1. "W" means broad gauge2. "D" means diesel motive power3. "M" means suitable for mixed(for both goods

and passenger)service4. "3A" means the locomotive's power is 3,100 hp ('3'

stands for 3000 hp, 'A' denotes 100 hp more) Or, in "WAP 5":1. "W" means broad gauge2. "A" mean AC electric traction motive power3. "P" means suitable for Passenger service4. "5" denotes that this locomotive

is chronologically the fifth electric locomotive model used by the railways for passenger service

DIESEL TRACTIONASSEMBLY AT DLW

Following types of diesel loco are being produced in the DLW:

1. WDM - Wide Diesel Mixed2. WDP - Wide Diesel Passenger3. WDG - Wide Diesel Goods4. WDS - Wide Diesel Shunter

WD

M C

LA

SS

Click icon to add picture

SPECIFICATION OF WDM CLASS

Power type Diesel

Builder Alco, DLW

Model DL560C

Build date 1962 onwards

Total production 2700+

UIC classification Co-Co

Gauge 1,676 mm (5 ft 6 in)

Wheel diameter 1,092 mm (3 ft 7.0 in)

Wheelbase 12.834 m (42 ft 1.3 in)

Length 17.12 m (56 ft 2 in)

Width 2.864 m (9 ft 4.8 in)

Height 4.185 m (13 ft 8.8 in)

Axle load 18,800 kg (41,000 lb)

Locomotive weight 112,800 kg (249,000 lb)

Fuel capacity 5,000 l (1,100 imp gal; 1,300 US gal)

Prime mover ALCO 251-B

Engine RPM range 400 - 1000 rpm

Aspiration Turbo-supercharged

Cylinders 16

Top speed 120 km/h (75 mph)

Power output 2,400 hp (1,800 kW)

Factor of adhesion 0.27

Disposition active

PERFORMANCE

The class WDM-2 is Indian Railways' workhorse diesel locomotive. The first units were imported fully built from the American Locomotive Company (Alco) in 1962. Since 1964, it has been manufactured in India by the Diesel Locomotive Works (DLW), Varanasi. The model name stands for broad gauge (W), diesel (D), mixed traffic (M) engine. The WDM-2 is the most common diesel locomotive of Indian Railways.

The WDM-2A is a variant of the original WDM-2. These units have been retro-fitted with air brakes, in addition to the original vacuum brakes. TheWDM-2B is a more recent locomotive, built with air brakes as original equipment. The WDM-2 locos have a maximum speed of 120 km/h (75 mph) , restricted to 100 km/h (62 mph) when run long hood forward - the gear ratio is 65:18.

WD

G C

LA

SS

SPECIFICATION OF WDG CLASSPower type Diesel-electric

Builder EMD & DLW

Model GT46PAC

Build date (EMD) 2001; (DLW) 2003–Present

Total production (EMD) 10; (DLW) 80+ under license (in production)

AAR wheel arr. A1A-A1A

Gauge 5 ft 6 in (1.68 m)

Trucks HTSC

Bogies •Bo-1-1-Bo (WDP-4)•Co-Co (WDP-4B and WDP-4D)

Fuel type diesel

Fuel capacity 6,000 liters

Prime mover 16-710G3B

Engine type 2-stroke diesel

Aspiration turbocharged

Displacement 11,360 in² (186.2 liters)

Alternator TA-17-CA6A

Traction motors AC

Cylinders V16

Transmission electric; AC alternator, 1 inverter per truck, AC traction motors

Power output •4,000 hp (WDP-4)•4500 hp (WDP-4B and WDP-4D)

Locomotive brakes air

Train brakes air

PERFORMANCE The WDP-4 is capable of hauling 24 coach trains at 110-

120 km/hour. It has also been used for speed trials where it has hauled 8 coach trains at 160 km/hour.

The locomotives can be used in either direction, and frequently haul trains long hood forward, as in the picture. Newer editions with 4500hp have been produced which have been named with the sub class WDP-4B /WDP-4D which have different traction control with six traction motors and are Co-Co bogie equipped, unlike the original which has a Bo-1-1-Bo arrangement with four traction motors.

The loco is very fuel efficient and has minimal exhaust emissions due to its 2 stroke diesel engine. It is characterized by its loud horn, which can be heard for large distances around, and aircraft-like sound of its running engine.

TRAINING PERIOD Following four workshop were assigned to me

during my training period of four weeks:1. Heavy Welding Shop2. Heavy Machine Shop3. Truck Machine Shop4. Heat Treatment Shop

HEAVY WELDING SHOP

In heavy welding shop steel sheets of about 75mm are welded together. To form engine block for both ALCO and GM engines. The conventional form of manufacturing engine blocks of such enormous size would have been very uneconomical.

The three main type of welding are:

1. Submerged Arc Welding (SAW)

2. Shielded Metal Arc Welding (SMAW)

3. Gas Metal Arc Welding (GMAW)

After welding the engine blocks are thoroughly inspected for under welding and over welding. Internal cracks are detected using NDT.

The blocks are then passed to HMS for further machining and boring of holes for cylinders or Power Pack Assembly. Generally 12 to 16 holes are bored.

HEAVY MACHINE SHOP

As the name suggests in the heavy machine shop the finished engine blocks are then machined upon to produce holes for power pack assembly.

The main machines in HMS are:1. Angular boring machine (TAL / HMT)2. CNC Portal milling ( Waldrich coburg)3. Radial Drill (max. 25 ton)4. Hydraulic press

HEAT TREATMENT SHOP

All the components used in an engine are heat treated before they are assembled. The main objective behind heat treatment is to improve the machinability and wear resistance of the components.

Some of the heat treatment used are :

1. Normalizing

2. Quenching

3. Carburizing

4. Induction hardening

NORMALIZIN

G

In the figure a normalizing furnace is shown.

NORMALIZING

In this heat treatment process the material is kept at a temperature 40° to 50 above critical temperature. This done due to following reasons:

1. To remove coarse grain structure 2. To remove internal stresses3. To improve mechanical properties

QU

EN

CH

ING

In the figure quenching tank is used.

QUENCHING

In quenching the material is heated to a temperature of about 815° to 900°C and then it is rapidly cooled by a mixture of water and polystyrene glycol.

The main advantage of quenching is to improve machinability, hardness and development of martensite structure. Generally all the components used in the locomotive are quenched before any other heat treatment process.

CA

RB

UR

IZIN

G

In the figure a carburizing furnace is shown

CARBURIZING OR CASE HARDENING

In this process a hard surface is produced on a low carbon steel of 0.15 percent carbon. In course of process the outer layer is converted into a high carbon steel with a carbon content ranging from 0.9 to 1.2 per cent of a carbon.

The components in the carburizing process are kept in contact with carbonaceous compounds and energizer (BaCO3). Then they are kept together in a furnace for a given period of time.

The hardness depends upon the penetration of carbon, temperature and time up to which its is kept in furnace. An hour of heating produces 4000 to 5000 hardness.

The main components which are carburized in the HTS are main piston pin, rocker arm assembly, crab bolts etc.

INDUCTION HARDENING

Induction hardening process is the heat treatment process in which components of high carbon percentage are hardened using high frequency ac current. Generally a p.d. of 200kv to 130kv is used.

In induction hardening process there is no change in chemical composition. The work piece is kept at a distance of 3-4 mm from the coils. The current produces a magnetic flux which produces eddy current resulting in heating.

I.H. is generally done on crankshafts who have a high percentage of carbon say about .45 to .48 percent.

SUGGESTIONS

The workshop is not user friendly. Congestion and lack of space. Safety and Security.