A

SUMMER TRAINING REPORT ON

“HMS, HWS, MA-1 & LPS”
AT
DIESEL LOCOMOTIVE WORKS, VARANASI
Submitted for partial fulfilment of the requirement for award of
BACHELOR OF TECHNOLOGY
Degree in
MECHANICAL ENGINEERING
By-
ALOK GUPTA
(Reg No-TTC/DLW/19/1033)

Kamla Nehru Institute of physical & Social Sciences, Sultanpur

Engineering Faculty

Department of Mechanical Engineering

KNIPSS Faculty of Engineering & Technology
Sultanpur (U.P) -228118
2018-19
 CERTIFICATE

This is to certify that Training report entitled, “HMS, HWS, MA-1 & LPS”
which is submitted by Alok Gupta in partial fulfillment of the requirement
for the award of degree B. Tech in department of Mechanical engineering
of AKTU University, is a record of the candidate own work carried out by
him under supervision. The matter in embodied in this summer training is
original and has not been submitted for the award of BTech degree.

Date:- A K Singh
HOD of Mechanical Engineering

Objective of the project is satisfactory / unsatisfactory

Examiner-1 Examiner-11
 DECLARATION

I Alok Gupta Roll no:-1638240003 student of B. tech (Mechanical

engineering) 3rd year of Kamla Nehru Institute of Physical and social
sciences, Sultanpur hereby declare that my training report on “diesel
locomotive works” is an original and authenticated word done by me and
the best of my knowledge and belief.

I further declare that it has not been submitted elsewhere by any

person in any of the institutes for the degree of Bachelor of
Technology.

Signature
ALOK GUPTA
ROLL NO: -1638240003
 ACKNOWLEDGEMENT

I would sincerely like to thank the employees and the officers of DLW,
Varanasi for their help and support during summer training. Despite their
busy schedule, they took out time for us and explained us the various aspects
of working of the plant from the production shops.

I would sincerely thanks to all who was instrumental in arranging the

vocational training at DLW, Varanasi and without whose guidance and help
the training could not have materlize.

I express my deep sense of gratitude to Ramjanm chaubey Principal TTC

DLW, Varanasi for giving me such a great opportunity.

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 PREFACE

The objectives of the practical training are to learn something about

industries practically & to be familiar with the working style of technical
person to adjust simply according to the industrial environment. It rightly
said practically life is far away from theoretical one. We learn in class room
can give the practical exposure or 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 & 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 & this report is
written on the basis of practical knowledge acquired by me during the period
of practical training taken at Diesel Locomotive Work, Varanasi.

ii
 CONTENT

ACKNOWLODGEMENT i

PREFACE ii

CHAPTER 1 INTRODUCTION 1

CHAPTER 2 BREIF HISTORY 3

CHAPTER 3 HEAVY MACHINE SHOP 4

CHAPTER 4 HEAVY WELDING SHOP 14

CHAPTER 5 MAINTENANCE AREA – 1 19

CHAPTER 6 LOCO PAINT SHOP 21

CHAPTER 7 CONCLUSION 23

CHAPTER 8 FUTURE SCOPE 24

CHAPTER 9 REFERENCES 25
 CHAPTER -1

INTRODUCTION

• Diesel Locomotive Works (DLW) established in 30 April 1956

located in the city Varanasi (U.P.) in 300 hectares

• Diesel Locomotive Works (DLW) manufactures the diesel electric

locomotive engine (EMD and ALCO) and DG sets.

• Diesel Locomotive Works (DLW) Certification

ISO 9001 (International Organization for Organization)

ISO 14001

OHAS 18001 (Occupational Health and Safety Zone)

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• Diesel Locomotive Works is production unit under the ministry of
railway. This was setup in collaboration with American locomotive
company (ALCO) USA in 1961 & the first locomotive was rolled out
in 1964.

• This unit products diesel electronic locomotive & DG sets for Indian
railways & other customers in India Abroad. Subsequently a contract
for transfer of technology of 4000HP Microprocessor Controlled
AC/AC Freight (GT 46 MAC) / passenger (GT 46 PAC)locomotive
& family of 710 engines has been signed with electromotive division
of GM of USA for manufacture in DLW is the only manufacture of
Diesel Electric locomotive with both ALCO & GM technologies in
the world.

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 CHAPTER -2

HISTORY OF DLW

The Diesel Locomotive Works(DLW) in Varanasi, India, is a production

unit owned by Indian Railways, that manufactures diesel-
electric locomotives and its spare parts. It is the largest diesel-electric
locomotive Manufacture in India. Locally it is abbreviated as D.L.W. It is
located in the Manduadih area on the outskirts of the metropolitan city
of Varanasi.

Diesel Locomotive Works is an ISO 9002 certified manufacturer of diesel

electric locomotive and is one of the biggest industrial complexes in eastern
part of the country. Diesel Locomotive Works was set up in 1961 with
technical collaboration from M/s. ALCO/USA with a modest beginning of
manufacturing 4 locos 1964, today DLW is the largest Diesel Locomotive
manufacturer in the world, and the largest in Asia. In order to capture export
market & widen its product range.

Indian railway entered in to a contract for Transfer of Technology (TOT)

with M/s. General Motors, USA for manufacture of 4000 HP state of the art
locos at DLW. After assimilation of this technology, DLW will become the
only factory in the world capable of producing ALCO as well as
General Motors designs of locomotives. DLW is only manufacture of diesel
–electric locomotive with both ALCO and GENERAL MO-TORS
Technologies in the world. DLW exports locos to SRILANKA,
MALAYSIA, BANGLADESH, TANZANIA, VIETAN-NAM.

3
 CHAPTER - 3

HEAVY MACHINE SHOP

This shop carries out the machining of Cycle BLOCK (M.G. & B.G.)
main base, saddler Main bearing caps, Splines, Turbo Super Charger,
Lube Oil, Fuel Oil & Water header) cam bearing housing.

3.1 OPERATION: -

Planning, Milling, Drilling, Tapping, Boring Honing, Serration

milling etc.

3.2 Types of Machine provided in the shop are: -

1. Double Housing planned machine (32”, 24’, &

16’).
2. Radial drilling machine.
3. Radial drilling machine Traveling type.
4. Boring Machine
5. Angular Boring Machine
(Excello)
6. Tracer Planner machine.
7. Hill Acme koing structural milling machine.

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3.3 TOOLS USE: -

1. O.K. Tool (Rough & Finish)

2. C.C. Milling cutter (4”, 9”, & 10”)

3. Boring Tipped Tool (Rough & Finish)

4. Honing Stone (For hand honing)

5. Drill, Reamer, Top (Various Seizer)
6. Serration Cutter.

3.4 MEASURING INSTRUMENT: -

1. Dial Bar gauge

2. Micron meter (outside and depth)

3. Vernier Height gauge.

4. Vernier callipers

5. Mandrill or optical shad rill machine

3.5 EX-CELLO ANGULAR BORING MACHINE: -

Motor R.P.M. in constant, Spindle, speed is control by clutch system.

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3.6 H.M.T. ANGULAR BORING MACHINE: -

Spindle speed is directly controlled through motor. (Coated carbide

is used in H.M.T. angular Boring machine)
Cycle Block made of fabricated class II material except main bearing
cop as it made class IV material. The machining of cycle Block is
complicated and challenging job. It required great skill and
knowledge. After duly fabricated, stress relieved and shot blasted the
block is subjected to layout to ensure availability of adequate
machining allowance, where necessary and to provide guide liner for
subsequent machining the weight of the block is 6.02 Tons approx.
(Fabricated Material).
After completion of all operations as per drawings the black subjected
to inspection in addition to stage inspection dimension live radial
distance between center of Crank bore and com bore, distance
between center of com bore and liner seat etc. are checked at this
stage the weight of the black is 05.02 tons apporx. 01 ton of material
removed by the machining and than blank is block send for assembly.

Fig: - 3.1

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3.6.1 Main dimension of cycle Block.

1. Dia. of com bore = 4.750” to 4.7515”

(B.G. & M.G.)
2. Dia. of blank bore = 9.0355” to 9.0370”
(M.G. & B.G.)
3. Dia. of liner bore = 10.750” to 10.752” (Upper)
(B.G. of M.G.)

= 10.621” to 10.623 (Lower)

4. Dia. of thirst Collar = 10*”

5. Thickness of thrust bearing = 4.247” to 4.249”
6. Thickness of the plate = free end = *”
= gen. End = 1*”
7. Radial distance between the centres of crank of
Cam bore = 10.499” to 19.501”
8. Distance of liner seat from centre of crank

Bore = 32.480” to 32.485”

9. Total length of the M.G. black
=106.370”
= 106.380”

10. Total length of main Bush B.G. = 172.380”

B.G.= 172.370”
11. Total length of main Bush M.G. = 117.130”
= 117.120”
12. Total length of B.G. Black = 161.625”
= 161.630”

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3.6.2 Main parts of the Cycle Block (B.G.)

1. Foundation Rail (R.S. AND L.S.)

2. Saddle ( 9 Nos)
3. Spline
4. Inner well (R.S. and L.S.)
5. Other well (R.S. and L.S.)
6. Top deck (Middle)
7. Top deck (R.S. and L.S.)
8. Side sheet (R.S. and L.S.)
9. Com bearing (16 Nos)
10. Cop (9 Nos.)
11. Rib (16 Nos.)
12. Bottom Deck. Or Middle deck (XIII) Fuel self comport.

3.6.3 Main parts of the Cycle Block (M.G.)

1. Foundation Rail (R.S. and L.S.)

2. Saddle – 7 Nos. (One Centre)
3. Top deck
4. Middle deck.
5. Side sheet (R.S. and L.S.)
6. Cam. Bearing 6 Nos.
7. Cap – 7 Nos.
8. Ribs – 10 Nos.
9. Fuel self comport.
10. Inner wall (R.S. and L.S.)
8
3.7 Horizontal Boring Machine: -
MW: - (no): 2155 & mw No: - 2154
Cam and Crank.
Boring of cylinder block crank and cam.

Fig: - 3.2
3.7.1 Method: -
Load the block on fixture.For checking weather there is any gap Or
not put the filler of size 0.001” to 0.0015” in side location pad. If there
is No gap then start work otherwise tight .The fixture and recheck till
no gap situation.

3.7.2 Boring of Cam Bore : (LS & RS):-

3.7.2.1 This is done in three steps: -

1.Rough Bore: - Do this in one pass

R.P.M.: 35 Feed: 6 mm/min.
2.Semi Finish Boring: - Do this in one pass
R.P.M.: 35 Feed: 6 mm/min.

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3.Finish Boring: -

Do this in one pass

Pass No. Bore No. R.P.M. Feed

1. 1, 4, 7, 10
2. 2, 5, 8, 224 25mm/min
3. 3.6.9.

3.7.3 Boring of Crank Bore:

3.7.3.1 This is also in three steps

1.Rough Boring : Do this in three pass.

Pass No. Bore No. R.P.M. Feed

1. 1, 4, 7, 14 5 mm/min
2. 2, 5, 8,
3. 3, 6, 9

2.Semi Finish Boring: Do in one pass

R. P. M.: 14 Feed: 5 mm/min

3.Finish Boring: Do in one pass

R. P. M.: 140 Feed: 25 mm/min

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3.7.4 Tool: -

Two tools are used for boring both tools are fixed in slot of boring
bar. Due to spindle rotation boring is done. Tool movement and
machine action is governed by G Code and M Code respectively.
Absolute mode and incremental modes are used for tool movement.
Single point cutting tool (two) is first fitted in devise block then in
boring bar.

3.7.5 Cutting Oil: -

Boring finishing operation cutting oil is used for smooth operation

3.7.6 Fixture: - J/F No: - FB (E) 15/2

3.7.7 Different: – Different tools are used in different step of Boring!

Crank: -
Rough Boring : 8.880”
Semi Finish Boring : 8-997”
Finish Boring : 9.035”

Cam: -
Rough Boring : 4.700”
Semi Finish Boring : 4.720”
Finish Boring : 4.750”

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Maximum removal of metal takes place in rough boring.
For making thrust (Cutting)
Tool Size : 10”
R.P.M. : 14
Feed : 22.86 mm/min
(.09”/min)

Tool material used in rough and semi finish boring is high speed steel
and in finish boring amended carbide.

3.8 Angular Boring Machine: -

M.W. No: - 1263
Angular Boring
Boring of Top deck bore and middle deck
bore:

3.8.1 Method: -

Load the block on fixture.

For checking weather there is any gap or not put the filler of the size
0.001” to 0.0015” inside location pad. If there is no gap then start
work otherwise tight the fixture and recheck till no gap situated.
Boring of Top deck Bore:

3.8.2 Tool: -

There are 18 tools are used. I tool in each side. Each are adjusted
automatically for rough cut and finish cut. During rough cut, finish
tool remains idle and during finish cut, rough tool remains idle. 7

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tools are fixed in each side in boring bar and two are replaced
according to demand of boring.

3.8.2.1 Different tools which are used are as

follows: -
1. M.I.D. Counter Insert No – TPUN –
160308
2. Rough – in mm – 190612 (weight) 190616 (yellow)
3. Liner seat rough TNMG 220412
4. T/D Chamfer P.G. 002 (only for 1263 m/c)
5. Liner seat finish – TPUN – 110308
6. Micro boring tool OOC No. 10A2LB
7. Counter insert wide no. – PNUN – 160402
8. T.I.D. Counter No. (Rough) – 1263 (N.C.)TN – 28
9. (TNUN 220 412)
10. 2187 M/c. – MIS Counter No. TNMM – 160408

Fig: - 3.3

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 CHAPTER - 4

HEAVY WELDING SHOP

This shop mainly deals with fabrication of the engine block and base (B.G & M.G)
Turbo support after cooler housing items. The engine block is structural member of the
diesel engine. It is composite weldment with heavy plates thickness varying from16
mm to 75 mm & steel forgives conforming to specification is 2062.The spine being
the most highly stressed item as we can say spine of the cylinder block is made out of
one piece bitted 5” * 7” thickness conforming to be 1895.

Fig: - 4.1

4.1 DIFFERENT WELDING PROCESS USED IN

HEAVYWELDING SHOP(H.W.S.)-

•Electric arc welding.

•Gas welding
•Forging welding.

Joining of two components by gas electric arc or forge of same or different material
homogeneous and dense joint is called welding.

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4.2 B l o c k s i n D L W - H W S -

4.2.1 ALCO (American Locomotive) block Power V Type

6 cylinder 2300hp Engine

12 cylinder 20600hp 45¶ alignment
16 cylinder 3300hp 45¶alignment

4.2.2 GM (general Motor) block or EMD (Electromotive Division)

block
Power
16 cylinder 4000hp
20 cylinder 5000hp

4.2.1. ALCO components

A. Saddle
No. of use width
Intermediate Saddle 07 4.5”
Center Saddle 01 6.75”
T Saddle 01 4.625”

B. Foundation Plate (L & R)

Two ends free and generator end L and R

Foundation plates are decided by Generator.

C. S p i n e s

D. Outside walls Width

L 20mm
R 20mm

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E. Middle deck Width
L 40mm
R 40mm

F. Inside wall Width

L 16mm
R 16mm

G. Top deck
L
R
In spine welding root run takes place from 1, 3, 5, 7, 9 and then 2, 4, 6, 8.In root
run,4.5 to 5mm electrode is used for welding. After root welding 6.5mm electrode
isused. X-ray quality joints are produced in ALCO.

4.3 W e l d i n g t y p e s i n H W S

1. Manual metal arc welding (MMAW)

2. Gas metal arc welding (GMAV)

3. Submerged welding ± shielding is provided by flux. On the basis of use

-Internal submerge welding
-External submerge welding

4. CO2 and agro shield (Argon 82% and CO2 18%).

CO2 creates shield and wt off the contact of flux from environment and prevent
oxidation of metal,

5. Tandem welding: -
Used for heavy metal deposition. Use A.C. and D.C. current both for welding. DC
arc lead AC arc transition welding process. Heat input is very low. Good penetration
is obtained. It is one time welding process while in internal and external submerged
welding the process can be repeated several times.

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 Fig: - 4.2

4.4 Stress relieving: -

After complete block fabrication heat treatment is done. We put block into diesel
furnace for 28hours.Temprature arises into diesel furnace. At rate 0f 50’per hour and
reach up to 450’C and then rises at the rate of 30’c per hour up to 640’c. At 640’cblock
is kept in furnace for 10 hours and its temp. Reaches at range of 250-280’c.

4.5 Coating: -

- Electrode is coated by iron dust and other filler material. Coating is done
for shielding of welding process.

4.5.1 Type of coating: -

1. Low coating ± Deposition efficiency 110%.

2. Medium coating - Deposition efficiency 110-129%
3. Heavy coating - Deposition efficiency 129-140%
4. Super heavy Coating - Deposition efficiency 140-220%.

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 Fig: - 4.3

4.6 Deposition Efficiency: -

It is defined as the ratio of amount of material included is weld to the amount of

material supplied.

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 CHAPTER - 5

MAINTENANCE AREA – 1

Maintenance is the action associated with equipment declared after its broken and also
maintenance follows the work of keeping something in proper condition .This implies
that maintenance should be a action that taken to prevent a device of component from
failing or to repair normal equipment degradation process with the operation of the
device.
To keep it in proper working order in DLW maintenance areas it is divided into two
section based on machine work as: -LMS and HMS
5.1 Type of maintenance
It is basically divided into two parts as follows; -
1. Breakdown maintenance
2. Preventive maintenance

5.1.1 BREAKDOWN MAINTENANCE

Breakdown maintenance is maintenance performed on equipment that has broken
down. Breakdown maintenance may be a planned or it can be unplanned.
Breakdown of machine can occur due to following two reason: -
1. Due to unpredictable failure of component which cannot be prevented.
2. Due to gradual wear and tear of the part of the machine which can be prevented by
regular inspection known as preventive maintenance.

5.1.2 PREVENTIVE MAINTENANCE

Preventive maintenance (PM) is fundamental planned maintenance activity design to
improve equipment life and avoid any unplanned maintenance activity also term as

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“planned maintenance” or “systematic maintenance” an extremely important function
production of maintenance cost and to keep the good operational condition of
equipment.

5.1.2.1 OBJECTIVE OF PREVENTIVE MAINTENANCE

1. Reducing shutdown period to maximum.
2. To keep the machine in proper condition so as to maintain the quality of product.
3. To ensure the safety of the worker.
4. To keep the plan at the maximum production efficiency.
5. To achieve the object the above objective with most economical combination.

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 CHAPTER - 6

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).

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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.

Fig: - 6.1

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 CHAPTER -7

CONCLUSION

The mechanical maintenance department is responsible for the running of

DLW. It ensures that the all the machinery and equipment are running at
their top performance level without being affected by failure and
breakdown. Working with the engineers of the mechanical maintenance
department I have gained such an amount of knowledge which wo. not have
been possible in a classroom in a similar period time. Also the practical
experience I have gained here in DLW, VARANSI gave me knowledge of
to what extent my theoretical knowledge learnt in my college is applicable
in the Although the theoretical knowledge forms the base of practical
knowledge required on the field , the field job also require some different
set of skills which I learnt about during my training. My skills in mechanical
engineering has definitely been taken to a much higher level than it was
when I first joined the training program of 4 weeks back and I truly consider
myself highly fortunate to get. opportunity.

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 CHAPTER - 8

FUTURE SCOPE

295 locos (1070 hhp diesel and 15 locos for NCR ) have been planned
to manufacture in FY 2018-19 as per Railway board mendate.

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 CHAPTER – 9

REFERENCES

1. www.dlw.indianrailways.gov.in

2. http://trainweb.org/railworld/DLW/

3. http://www.scribd.com/doc/64559155/Report-on-Summer-Training-
at-Dlw-Varanasi

4. http://www.scribd.com/doc/54456974/Summer-Traning-DLW-
Report

5. http://www.scribd.com/doc/45187594/Summer-Training-Diesel-
Locomotive-Works-Ppt

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