GAUTAM BUDDHA UNIVERSITY

Greater Noida, Gautam Buddha Nagar UP 201312

Established by the Uttar Pradesh Gautam Buddha University Act 2002 UP Act No.9 of 2002
(Approved by UGC under Section 12-B.NAAC accredited with B+ Grade)

A
SUMMER TRAINING REPORT
ON
DIESEL LOCOMOTIVE WORKS VARANASI
In partial fulfilment of the requirement for the award of degree of

BACHELOR OF TECHNOLOGY MECHANICAL ENGINEERING

Submitted By: Training Duration: 6 weeks

ANAND SINGH YADAV (04/06/2019 to 15/07/2019)
Registration No. TTC/DLW/19/49 Training Area:
Semester VI ETS, LTS, LFS, LPS, HMS, HWS
 ACKNOWLEDGEMENT

I would sincerely like to thank the employees and the officers of DLW,
VARANASI for their help and support during the vocational training. Despite
their busy schedules, they took time out for us and explained to us the
various aspects of the working of the plant from the production shops.
I express my deep sense of gratitude to Mr. Ramjanm Chaubey
(Principal, TTC) for given me such a great opportunity.
 PREFACE

The objectives of the practical training are to learn something about

industries practically and to be familiar with the working style of a
technical person to adjust simply according to the industrial
environment.

It is rightly said practical life is far away from theoretical one. We

learn in class room can give the practical exposer real life experience
no doubt they help in improving the personality of the student, but the
practical exposure in the field will help the student in long run of life and will
be able to implement the theoretical knowledge.

As a part of academic syllabus of four-year degree course in Mechanical

Engineering, every student is required to undergo a practical training. I am
student of third year mechanical and this report is written on the basis of
practical knowledge acquired by me during the period of practical
training taken at Diesel Locomotive Works, Varanasi.
 CONTENTS

[1]. Introduction to DLW

[2]. Engine Test Shop

[3]. Loco Test Shop

[4]. Loco Frame Shop

[5]. Loco Paint Shop

[6]. Heavy Machine Shop

[7]. Heavy Weld Shop

[8]. Bibliography
 INTRODUCTION TO DLW
Diesel Locomotive Works (DLW) is a 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 GENERL 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.
 Brief History:
• Set up in 1961 as a green-field project in technical collaboration with
ALCO/USA to Manufacture Diesel Electric Locomotives.
• First locomotive rolled out and dedicated to nation in January 1964.
• Transfer-of-Technology agreement signed with General Motors/ USA
in October 1995 to manufacture state-of-the-art high traction AC-AC
diesel locomotives.
• A flagship company of Indian Railways offering complete range of
flanking products in its area of operation.
• State-of-the art Design and Manufacturing facility to manufacture more
than 150 locomotives per annum with wide range of related products
viz. components and sub-assemblies.
• Unbeatable trail-blazing track record in providing cost-effective, eco-
friendly and reliable solutions to ever-increasing transportation needs
for over three 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. Sri
Lanka, Malaysia, Vietnam, Bangladesh, Tanzania to name a few,
bearing testimony to product leadership in its category.
 SALIENT FEATURES:

Annual production capacity 125Locomotives

Annual turn-over (Rs) 5000 million
Total number of staff 7223
Workshop land 89 Hectares
Township area 211Hectares
Covered area in shops 86300 𝑚2
Covered area of other service buildings 73700 𝑚2
Electrical power requirement 3468 KVA
(Average maximum demand)
Electrical energy consumption (units/year) 19.8 million
Standby power generation capacity 3000 KW
 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 400 HP AC/AC Broad Gauge Mixed Traffic
Microprocessor 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.
• 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.
 DIESEL LOCOMOTIVE DIAGRAM

STORE DEPARTMENT: After receiving of ML, Store Departments scrutiny

the ML, take Funds & vetting from Account department & then issue tenders,
Open Tenders & Purchase Order issued. After Receiving of Material,
inspection has done by Inspection Department.
INSPECTION DEPARTMENT: After Receiving of Material inspection has
done by Inspection Dep’t. If material is OK then Receipt Note issued by Store
Dep’t and sent to Acct. Department for payment to firm. If material is not OK
Then, inform to firm to collect the rejected material.
ACCOUNT DEPARTMENT: Check all the purchase, given concurrence for
purchase, vett the ML/Requisition & payment to firms.
PLANNING OFFICE: Prepare JPO, Monthly Production Program,
Scheduling, Processing, Rate Fixing, Issue Work Orders, Schedule Orders,
Issue Job card & other production Documents. Preparing DLW Budget &
Sent to Rly Board.
PROGRESS OFFICE: After opening of work, orders collect the prod.
Documents from PCO and hand over to user shop draw the material from
depot & given to shop & hand over the ready material of shop to user
shop/store. After completion of work, close the work order.
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 Assembly Shop
5. Rotor Shop
6. Heat Treatment Shop
LOCO DIVISION:
1. Loco Frame Shop
2. Pipe Shop
3. Truck Machine Shop
4. Traction Assembly Shop
5. Sheet Metal Shop
6. Loco Assembly Shop
7. Loco Paint Shop
8. Loco Test Shop
SERVICE SHOPS:
1. Maintenance Areas#1, 2, 3
2. Tool Room
3. Central Transport Shop
PERSONNAL DEPARTMENT: Prepare payment of Staff, Leave Record,
Personal Record of every employee, Housing allotment, welfare of staff etc.
HEALTH DEPARTMENT: Having facility of Indoor & Outdoor patients.
CIVIL DEPARTMENT: Maintenance of colony quarters, up gradation of
facilities in quarters, sanitation etc.
ELECTRICAL DEPARTMENT: Maintenance of Lighting in quarters and in
workshop, electrical works in locomotive etc.
TECHNICAL TRANING CENTER: Provide training to all employees at time
to time to refresh update their knowledge.
RESEARCH &DEVELOPMENT:
1. R & D - a Customer centric Activity Committed to Innovation and
Continuous Improvement;
2. Highly skilled Manpower capable of handling complete R&D activities;
3. A sophisticated design centre with modern CAD/ CAE workstations
equipped with Unigraphics and Ansys;
4. Back-up support from RDSO, a centralized R&D organization at corporate
level;
5. Several milestones in the past - an enviable pedigree viz.
(a). original ALCO design made 7% more fuel efficient;
(b). many design improvements leading to better performance,
 incorporated in the original ALCO design.
RECENT MILESTONES & FUTURE PLAN:
MILESTONES ACHIEVED:
Transfer of technology (TOT) -- An added feather in the cap:-
• Agreement with General Motors of USA for technology transfer to
manufacture high horse-power GT46MAC 4000HP AC/AC locomotive
in India;
• Only country outside North-America to have this bleeding edge
technology Many export/repeat orders complied successfully in recent
past and many more in the pipeline; Supplied more than 400
locomotives to various non-railway customers; Emerging as a leading
manufacturer of ALCO/ GM locomotives for developing countries.
FUTURE PLANS:
• Assimilation of GM technology to manufacture their latest 710 series of
diesel electric locomotives;
• To emerge as a globally competitive locomotive manufacturer;
• To develop as an export hub for ALCO/ GM locos for Asian market;
• To follow an export led growth strategy through continuous improvement;
Cost effectiveness and technology/ product up-gradation as a key to retain
global competitiveness by putting price-value-technology equation right.
 ENGINE TEST SHOP
After ensuring no leakage in water, fuel & oil circuit on Pre Test Stand, engine
is tested on Engine Test Bed for testing of all the functional parameters of
Engine. Alternator is attached separately to the Engine for testing purpose by
placing it on a trolley. Process of Engine Testing goes through monitoring and
recording of various performance parameters by running the engine at eight
different notches for a pre-defined period. After completion of testing, the
Engine is painted before despatching it to loco assembly shop.
 LOCO TEST SHOP
Fully assembled locomotive is sent to Loco Test Shop for complete testing
before it is dispatched to the customer. Testing of locomotive involves
mechanical & electrical equipment load test, air brake test, electrical track
test, Shower Test, RRT (Rode Run Test), etc. Finally, the locomotive goes to
pre-dispatch inspection before final dispatch for service.
 LOCO FRAME SHOP
Under-frames are fabricated using heavy fixtures and positioners to ensure
down hand welding to achieve designed weld strength. Requisite camber to
the under-frame is provided during fabrication itself. Critical welds are tested
radio-graphically. Welder training and their technical competence are
periodically reviewed. New loco frame shop is equipped with modern paint
booth along with remote controlled hydraulic trolley for movement of under-
frames.
 LOCO PAINT SHOP
DLW has state of art modern Paint Booth having automated technology for
PU painting of the locomotive. The Paint booth provides safe & better working
environment for operators in Paint booth through clean air supply, efficient
exhaust systems, maintaining the temperature in comfortable range (25-
30°C) with R.H. (60-80 %) of spraying booth. Paint booth can be operated in
both Auto & Manual mode with operating panel. Paint booth equipped with 2k
spray painting equipment to enhance the painting quality. It is also equipped
with three dimensionally operated man lift, to make it easier for the operator
to approach locomotive sides & roof areas to be painted in the booth. To
expedite the intervening requirement of paint drying before application of next
coat, drying oven has been provided. The drying is carried out in dust free
environment. This reduces the cycle time of painting operation & enhances
the painting quality. Drying oven provides hot air circulation in close loop
cycle, bearing temperature 70-80°C in a close surrounding. Close loop cycle
prevent heat losses of circulating hot air & consume less fuel (Diesel). To
transport locomotive between heating oven and paint booth, a pit type
traverser of carrying capacity of 150 T has been installed. It facilitates shifting
of locomotive between Paint Booth to Drying Oven.
 BLOCK DIVISION (HMS)
INTRODUCTION: Block Division is one of the most sophisticated and
technically advanced divisions of DLW, which is engaged in production of
HHP Crankcase, Broad Gauge and Meter Gauge Alco Blocks. Advanced
welding & machining techniques are being used in manufacturing of HHP
crankcase. It is mainly equipped with CNC Flame Cutting Machines, Sub-
merged Arc Auto welders, Welding Machines, several CNC Machining
Centres and Coordinate Measuring Machine.
Flame Cutting of Components
Steel plates of sizes up to 80 mm thickness are ultrasonically tested before
being precision cut by numerically controlled flame cutting machines, Plasma
Cutting Machine. Components are straightened and machined prior to fitting
& tacking on fixture designed especially for engine block fabrication to ensure
close tolerance on engine block.

Fabrication of Engine Block/ Crankcase (HMS)

Components after flame cutting and various machining operations are fit and
tack welded before taking on rollovers. Heavy Argon-CO2 welding is done on
these rollovers. High quality of welding is done by qualified welders. Weld
joints are subjected to various tests like ultrasonic, X-rays, Visual etc. Down-
hand welding is ensured using specially designed positioners. Fabrication of
Engine block/HHP Crankcase is completed by submerged arc welding using
semi-automatic welding machines. Special fixtures are used for making
downhand welding possible in inaccessible areas. Critical welds are
subjected to radiographic examination. All welders are periodically tested and
re-qualified for the assigned period.
After complete welding, marking is done on the weldment for subsequent
machining & desired build-up. Weldment is stress relieve, shot blasted and
sent to Heavy machine shop for final machining.

Portal Milling Machine (HMS)

HHP Crankcase machining is done on Portal milling machine which is 19
axis CNC machine having SIMENS 840 Dsl control system. This machine is
equipped with 05 attachments (head) that are vertical head, horizontal head,
universal head, serration head and boring head along with automatic tool
changer with 100 pocket tool magazine which make this machine to do any
type of machining work in auto mode with very high accuracy. This machine
is also supported by 40 minutes battery backup to protect machine and work
piece in case of sudden power failure.
Angular Boring Machine
Angular boring or Liner boring of Crank case is done on this special purpose
machine, which has two high precision angular boring bars at 45 degree on
which different boring cartridge inserts are mounted. The machine is capable
of boring and drilling to different sizes. The cartridge with inserts is mounted
on boring bars to achieve evenly distributed cutting load during boring
operation. This contributes to accuracy while machining.

Quality Control
In process, inspection is being conducted after every stage of
fabrication/machining. Crankcase is sent to next stage only after successful
inspection of previous stage. Machined Crankcase is finally inspected at
Computer Controlled Coordinate Measuring Machine prior to dispatch for
Engine Assembly.
 HEAVY WELD SHOP
In the DLW there are basically three type of welding used in HWS. The
welding quality of DLW is very high quality. After the machining process, we
can’t say that this piece is not single piece.
1. Submerged arc welding
2. Manual metal arc welding
3. MIG welding
SUBMERGED ARC WELDING:
In submerged arc welding the welding process will be covered with the flux so
that it will not react with oxygen and nitrogen. Because of the versatility of the
process and the simplicity of its equipment and operation, shielded metal arc
welding is one of the world's most popular welding processes. It dominates
other welding processes in the maintenance and repair industry, and though
flux-cored arc welding is growing in popularity, SMAW continues to be used
extensively in the construction of steel structures and in industrial fabrication.
The process is used primarily to weld ironand steels (including stainless
steel) but aluminium, nickel and copperalloys can be welded with this
method.
MIG WELDING:
MIG welding can be used for most types of metals; steel, stainless steel, as
well as aluminium. But welding aluminium is very different from welding mild
steel because aluminium is a metal that is different from steel. So when we
weld aluminium, we have to use other parameters, other settings. Aluminium
has a lower melting temperature than mild steel, for example, so you should
expect that we should use a lower heat input but in spite of this. So we have
to use a higher local heat-input but a faster welding speed than with steel to
get good fusion and penetration. This sounds as if aluminium welding is
difficult, but it's not. The welding sets that we use adjust the welding
parameters automatically, so the welder can concentrate on the welding
operation, the movement of the welding gun and the weld pool.
 BIBLIOGRAPHY
1. https://dlw.indianrailways.gov.in
2. https://www.google.com
3. https://www.slideshare.net