A

SUMMER TRAINING REPORT

AT

BANARAS LOCOMOTIVE WORKS

VARANASI
Submitted to a Faculty of School of Mechanical Engineering (SMEC)
Vellore Institute of Technology, Vellore

in partial fulfilment of the requirement for the award of degree of

Bachelor of Technology in Mechanical Engineering
By
GAURAV KUMAR PANDEY
(Register No.: 19BME0538)

Under the guidance of

Ashok Kumar (CWI/Weld)
Technical Training Centre
Banaras Locomotive Works (BLW), Varanasi
1. DECLARATION
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I GAURAV KUMAR PANDEY (Register No.: 19BME0538), student of
B.Tech (Mechanical Engineering) 2nd year of Vellore Institute of Technology,
Vellore hereby declare that my project report on “BANARAS LOCOMOTIVE
WORKS” is an original and authenticated word done by me. I further declare
that it has not been submitted elsewhere by any person in any of the institutes
for the degree of bachelors of technology.

As per of my instructor this report will focus on HWS (Heavy Weld Shop), EES
(Engine Erection Shop), LFS (Loco Frame Shop) and LAS (Loco Assembly
Shop) which is therefore submitted by me for the course ‘Industrial Internship’
(MEE1902) under University Core to VIT is a record of bonafide work carried
out by me under the supervision of Mr. ASHOK KUMAR (CWI/Weld).

Place: BLW, Varanasi

Date: 29 / 07 / 2021
2. ACKNOWLEDGEMENTS

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I express my profound gratitude to my HOD, Department of Manufacturing
Engineering Prof. AK Jeevanantham and VIT (Vellore Institute of Technology)
University for enabling me to complete my Industrial Internship.
I express my deep sense of gratitude to Mr. M.P.Singh (Principal, TTC) for
giving me such a great opportunity.
I'm also grateful to BLW officials CWI/Weld - Mr. Ashok Kumar, SSE/HWS -
Mr. Chauhan, SSE/EES - Mr. Yogendra Pal and my internship guide Mr.
Rakesh Pandey for their kind attention and consistent support towards me
during the internship.
My thanks and appreciations also go to my respective colleague in finishing this
report and people who have willingly helped me out with their abilities and
helped me a lot in gathering different information, collecting data and guiding
me from time to time in making this report, despite of their busy schedules, they
gave me different ideas in making this report unique.

Best regards:
Gaurav Kr. Pandey

TABLE OF CONTENTS
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 Page No.
1. Declaration ------------------------------------------------------------------ 2
2. Acknowledgement --------------------------------------------------------- 3
3. Preface ------------------------------------------------------------------ 5
4. Overview ------------------------------------------------------------------------ 6
5. Introduction to BLW ---------------------------------------------------------- 7
6. Products at BLW ------------------------------------------------------------ 8
7. Identification of locomotives at BLW ------------------------------------- 9
8. Divisions of BLW ----------------------------------------------------------- 10
9. Heavy Weld Shop (HWS) ------------------------------------------------- 11
10. Electric Loco Bogie Fabrication ------------------------------------------- 16
11. Steps in fabrication of Bogie --------------------------------------------- 19
12. Engine Erection Shop (EES) ---------------------------------------------- 21
13. Zinc Die Casting in Cars: Modern Lifesaver … ------------------------- 23
14. Applications of Zinc Die Casting in the Automotive Industry --------- 26
15. High fluidity zinc die casting alloy ---------------------------------------- 29
16. Summary -------------------------------------------------------------------- 31
17. Conclusion -------------------------------------------------------------------- 32
18. References -------------------------------------------------------------------- 33

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 3. 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 that can help in gathering knowledge and then improving the personality
of the student, but the practical exposure in the field will help the student in
long run of life by acquiring knowledge through hands-on-experience by taking
up Internship in renowned organizations. It will also provide opportunity for the
students to learn and follow the good industrial practices.

As a part of academic syllabus of 4 year degree course in Mechanical

Engineering, every student is required to undergo a practical training.
I am student of 2nd year mechanical and this report is written on the basis of
practical knowledge acquired by me during the period of practical training taken
at Banaras Locomotive Works (BLW), Varanasi.

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 4. Overview
In this report, I have covered the following: Introduction of BLW, its
achievements and a detailed overview of the four major shops that were
assigned to me during my internship period viz. HWS (Heavy Weld Shop), EES
(Engine Erection Shop), LFS (Loco Frame Shop) and LAS (Loco Assembly
Shop).
Since my overall internship was lasted for 28 days, so I had been briefed on
each of the above mentioned shops for a maximum duration of 1 week.
I had also examined the entire workflow in the respective shops with hands on
training about the machines. I also tried to gain some work experience, build up
soft skills, hold leadership roles (wherever was necessary), and had answered
relevant questions during the interview with SSEs (Senior Section Engineers).
I could say that after the completion of my internship programme, I gathered a
deeper theoretical knowledge with practical skills in respective areas. Not only
this, but also I can grab an opportunity in future to work on real-life projects.
I’ve learned more about the industry, and had developed the essential skills
needed to progress within their field.

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 5. Introduction to BLW
• Banaras Locomotive Works (BLW) previously known as Diesel Locomotive
Works (DLW) is a production unit under the ministry of railways. The change
in name of this organisation took place because of the following reasons:
(a)- Diesel fuel (refined from crude oil) produces many harmful emissions when
it is burned, and diesel-fueled vehicles are major sources of harmful pollutants,
such as ground-level ozone and particulate matter. So, to stop the impact of
environmental pollution causing by this engine, this step was taken.
(b)- Electric engine runs faster than the diesel engine which also adds a cap in
the advantages of electric engine over diesel engine.

• DLW, was founded by Late Railway Minister Mr. Lal Bahadur Shastri on 23
April 1956. It is spread in 300 acres area at Varanasi.
• DLW 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.

• Got its first ISO certification in 1997 and ISO-9001 and ISO-14001 in
December 2002. With technology transfer agreement from manufacturers such
as GM-EMD, BLW today produces advance locomotives having output range
from 2600 to 4000 HP.
•At present (in 2020) the latest locomotive produced by BLW: developed the
country's first bi-mode locomotive, the WDAP-5. BLW today produces mostly
electric locomotives WAP-7 & WAG-9.
•BLW is supplying locos to PSU’s & Industries like NTPC, COAL,
INDOGULF etc. BLW is the only manufacturers of Electric Locomotives with
both ALCO and General Motors technologies in the world.

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 6. Products at BLW
BLW 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.
 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.

7. Identification of locomotives at BLW

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Following types of diesel loco are being produced in the BLW:-
WDM- Wide Diesel Mixed, WDP- Wide Diesel Passenger, WDG- Wide
Diesel Goods, WDS- Wide Diesel Shutter
The First Letter (Gauge):
 W- Indian broad gauge (The “W” stand for wide Gauge- 1.67m)
 Y- Meter gauge (The “Y” stands for Yard gauge- 1m)
 Z- Narrow gauge (0.762m)
 N- Narrow gauge (0.610m)
The Second Letter (Motive Power):
 D- Diesel
 C -DC Electric (can run under DC traction only)
 AC Electric (can run under AC traction only)
 CA- Both DC & AC (can run under both AC & DC tractions) 'CA' is
considered as single letter
 B- Battery Electric locomotive (rare)
The Third Letter (Job Type):
 G- Goods
 P- Passenger
 M- Mixed, both goods & passenger
 S- Shunting(also known as switching engines)
 U- Electric multiple units (used as commuters in city suburb
The Fourth Number describes Horse Power in 1000’s.
The fifth letter describes additional HP in 100’s.

For an example: WDM3A signifies------------------------

• "W" means broad gauge
• "D" means diesel motive power
• "M" means suitable for mixed (for both goods and passenger) service
• "3A" means the locomotive's power is 3,100 HP… (‘3’ stands for 3000 HP,
‘A’ denotes 100 HP more).

8. Divisions of BLW

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At BLW, 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

9. HWS (Heavy Weld Shop)

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This section was my first and foremost exposure to the field industry. This area
comprises of works generally related to welding and stuffs. As the name
depicts, this area, which is also known as shop was exposed to take welding
applications which uses in fabrication of loco bogie and their sub-assemblies.
This shop mainly deals with the fabrication of the engine block and base (B.G.
& M.G.) Turbo support. After cooler housing items. The engine block is the
principal, structural member of the diesel engine. It is composite weldment with
heavy plate’s thickness varying from 16 mm to 75 mm
What is welding joint?
An arrangement or configuration of two metal plates that will be fitted together
is referred to as a welding junction. Welding may be used for a variety of
reasons, and various procedures that demand different types of welds and
connections.
Different welding processes used in HWS are:
I. Submerged Arc Welding (SAW) - Arc welding is a welding process that
is used to join metal to metal by using electricity to create enough heat to
melt metal, and the melted metals when the cool result in a binding of the
metals.
By applying intense heat, metal at the joint between two parts is melted and
caused to intermix directly, or more commonly, with an intermediate molten
filler metal.

From the
Diagram some
equipment or
parts used in the
Arc welding
process you can
see and some are
not shown in the
diagram which
also I am going to
explain.
The main parts of Submerged Arc Welding are:
 Consumable Electrode: It is the electrode which is having current on it and
when it’s touching to the workpiece it gets melt there.

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 Power source: For the operation of welding, power is required to generate a
good amount of heat so that workpiece and electrode can melt easily (Spark
produces between them)
 Granular Flux: The main function of Granular flux is to avoid the exceeding
heat, which is generated when electrodes touch to the workpiece.
 Base Metal: The base metal is metal on which have to weld it might be:
Carbon steels (structural and vessel construction), Low alloy steels, Stainless
steels, Nickel-based alloys
 Electrode Holder: The main works of this are to hold the electrode. This
device is a non-conductor device.

II. Shielded Metal Arc Welding (SMAW) - In shielded metal arc welding
(SMAW), an arc between a covered electrode and a weld pool is used to
accomplish a weld. As the welder steadily feeds the covered electrode
into the weld pool, the decomposition of the covering evolves into gases
that shield the pool. The process is used without application of pressure
and with filler metal from the covered electrode.

The SMAW process uses an

III. Metal Inert Gas Welding (MIG) -
Metal Inert Gas (MIG) welding is
an arc welding process that uses a
continuous solid wire electrode
heated and fed into the weld pool
from a welding gun. The two base
materials are melted together
forming a join. The gun feeds a
shielding gas alongside the
electrode helping protect the weld
pool from airborne contaminants.
electric circuit that supports a
welding arc to convert electric
line power or fuel into heat. The
heat from the welding arc is
intense and extremely
concentrated. It instantly melts a
portion of the workpiece and the
end of the electrode. The welder
maintains the arc length by
holding a consistent space
between electrode and weld pool
that forms on the workpiece.
When the arc is removed, the
liquid fuses and the melt
solidifies into continuous metal.

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 An arc is struck between the end of
a wire electrode and the workpiece,
melting both of them to form a
weld pool. The wire serves as both
heat source and filler metal for the
welding joint. The wire is fed
through a copper contact tube
(contact tip) which conducts
welding current into the wire. The
weld pool is protected from the
surrounding atmosphere by a
shielding gas fed through a nozzle
surrounding the wire.

10. Electric Loco Bogie

Fabrication
 Purpose of Bogie: Each bogie is a 4-wheeled or 6-wheeled truck that serves
a number of purposes:
a. To provide Support of the rail vehicle body.
b. To ensure enough stability on both curved and straight road.
c. To improve ride quality by absorbing vibrations and
minimising the impact of centrifugal forces when the train
runs on curved path at a high speed.

Fig.: Exploded View of WAP-7 Bogie

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Raw materials used in HWS shop are:
 Steel plates of IS: 2062: E410 – Total 11 types of different dimensions
of plates are used here (viz. 10 mm, 12 mm, 16 mm, 18 mm, 20 mm,
25 mm, 32 mm, 40 mm, 50 mm, 60 mm, 63 mm).
 Steel plates of IS: 2062: E250 SAILMA - Total 4 types of different
dimensions of plates are used here (viz. 3.15 mm, 6 mm, 10 mm, 66
mm).
 Steel round bar 50 mm IS: 1875: Class VI)

Main Sub Components used: There are a total of 11 components are used
here which they assemble by welding process while fabrication of loco bogie
-
 Spring Guide, Tube T211/203
 Pivot
 Sealing Copper Washer
 Bar for bogie head beam
 Hex socket CSK screw
 Dowel Pin
 Round bar diameter 28 mm
 Kit of bushes for brake
 Tube for head beam assembly
 Liner non metallic
 Motor support

Filler material used:

 SAW Flux – L-780
 0.32 mm Grade L-50 Lincoln weld SAW wire
 1.2 mm MCAW (Metal cored arc welding) wire
 0.9 mm Solid Copper coated wire
 4.0 mm E-6011 Wire (used in tacking)
 9.0 mm gauging rod (for repairing)
 82% Argon and 18% CO2 gas (Shielded gas)

Main Sub-Assemblies of bogie frame assembly:

 Side Frame RS (right side) and LS (left side) – 1 No. each
 Transom – 2 No.
 Pivot Transom – 1 No.
 Head Beam assembly – 1 No.

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  Brackets and components
Steps in fabrication of Bogie:
1. Setup and tack weld of all sub assembly components of Bogie.

2. SAW welding of all sub assembly components of Bogie.

3. Straightening and machining of all sub assembly components of Bogie.

4. Marking, setup and tack of Bogie assembly on Bogie assembly fixtures.

5. GMAW welding of Bogie assembly on Bogie assembly fixtures.

6. Ultra-Sonic Testing of all critical welding joints.

7. Setup and tack weld of components on Bogie before Stress Relieving.

8. Stress Relieving process of Bogie assembly. {This happens at maximum 640

degree Celsius. The total time duration of this cycle is 28 hour which comprises
of 14 hours of heating cycle, 10 hours of cooling time and 4 hours of soaking
time}.
The furnace is capable to accommodate to B.G. block at a time. As the engine
block in machined to very close tolerances. It is necessary that all stresses
developed during the fabrication stages are completely relieved before
machining. This would ensure a longer life in service without any distortion
which would normally result on account of very alternating stresses that the
engine block is subjected to during its service.

9. Shot blasting of Bogie assembly. {All rust and impurities with carbon
particles are removed here}.

10. Machining of Bogie assembly.

11. Setup and tack weld of different brackets and components on Bogie
assembly.

12. Final inspection of Bogie assembly.

13. Dispatching of Bogie for painting and loco assembly.

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 Sequence of Side Frame fabrication:
(a) We can see there are two plates i.e. top plate and bottom plate. Firstly the
bottom plate is mounted on the fixture.

(b) Then the different cross plates, supports are tack welded further.
(c) Later they are welded together and then cross webbed (12 mm thick plate
key). (d) And then we can see that on the final stage, a box like structure has
been prepared by following those several steps.

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(e) Then this boxes are send for SAW and there the complete welding of these
boxes takes place.

 Sequence of Transom and Pivot Transom Fabrication:

(a) The assembly of pivot transom to the Bogie is also an essential part of the
assembly. These are 2 in numbers.

(b) In the first figure, bottom plate is placed. After that, side cross webs and top
plate are placed and then tack welded together.

(c) Then the whole fixture is SAW welded together completely.

 Sequence of Head Beam assembly setup & Tack weld:

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(a) In this assembly, the components which they are using and related steps can
be seen in the given figure.
(b) On the left side, a bar consists of collar is tacked and welded using SAW
process.

(c) Then this bar is placed inside a tube and finally the tube is then assembled.

 Straightening operation of side frame:

(a) Here the side frames after being welded using SAW process is made to go
through this operation.

(b) The side frames are brought to the surface where the frames must have to be
straight.

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(c) The twisting, convexing and concaving of each frame are then completely
eliminated using this operation.
(d) Later these frames are sent to the machining operation for further processes.

 Radiographic Joint of Bogie:

(a) A total of 12 in number of this is sued in the fabrication of loco Bogie.
(b) Also the welding used in previous process is being tested for UST
(Ultrasonic testing).

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(c) They are complete joint and are single V butt weld.

 Bogie Assembly setup and tack weld operation:

(a) Here all the previous components i.e. RS frame, LS frame, 2 No. Transom, 1
No. Head beam, 1 No. Pivot Support are brought to a fixture called assembly
fixture.

(b) As we can see in the figure, these all components are then tack welded.
(c) Also Head Beam assembly is also assembled here.

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(d) Now this whole as a bogie assembly is ready to go for radiography testing
for the areas where welding and critical joints has been formed.

 Marking of Bogie to set up components before Stress relieving

process:
(a) When welding is completed, critical welding inspection has tested
successfully and radiograph results are good then this bogie is brought for
marking.

(b) In marking, main components are welded but before that this Bogie are
made prepared to go for stress relieving.

 Bogie during Stress relieving:

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(a) In the figure, it can be seen that Bogie is brought for stress relieving and is
placed under the furnace.

(b) To have a production at faster rates, two Bogie at a time are placed inside
the furnace for SR purpose.
(c) This happens at maximum 640 degree Centigrade temperature. The total
time duration of this cycle is 28 hour which comprises of 14 hours of heating
cycle, 10 hours of cooling time and 4 hours of soaking time.
 Shot blasting process of Bogie:
(a) All the rusts, fluxes and impurities are removed and cleaned here.

(b) After this shot blasting process, the Bogie is then sent for the further
machining operation.

 Bogie after Machining:

After all the holing, drilling and others machining operations on Bogie was
done, it is then sent again to welding section.

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 Final setup and tack weld of final components:

(a) Here different components like brackets, axle guide and others more
components are tack welded at different position and setup is done by
application of welding process like down end welding, horizontal welding and
vertical welding.

(b) These components (axle guide, brackets and pivot support) are already being
made solely alone and then assembled at this step.

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