SHELL MANUFACTUIRING

FOR LOCOMOTIVE ENGINE

MODEL WAP-7
 OVERVIEW OF LOCOMOTIVE ENGINE
MODEL WAP-7

 The WAP-7 is one of the most successful locomotives of Indian Railway that was developed in 1990 by
Chittaranjan Locomotive Works [CLW], currently serving as passenger trains engine.
 BUILDERS: 1. Chittaranjan Locomotive Works [CLW].
2. Banaras Locomotive Works [BLW].
3. Diesel Loco Modernisation Works [DLW]
4. Bharat Heavy Electricals Limited [BHEL].
 DIMENSIONS: 20.934m [L] X 3.179m [W] X 4.185m [H].
 MAX. SPEED: 120 Km / h
 OUTPUT POWER:5500 hp [4100 KW]
 MAJOR PARTS OF SHELL ASSEMBLY.
[ DRAWING No. – IB031-00273 ]

 UNDER FRAME ASSEMBLY. – 1 N0.

 CAB STRUCTURE. - 2 NOS.
 BODY SIDE WALL [RHS]. - 1 NO.
 BODY SIDE WALL [LHS]. - 1 NO.
 ROOF HATCH ASSEMBLY. - 1 NO.
 DRIVER DECK ASSLY. - 2 NOS.
 FLOOR DUCTING. - 1 SET.
 PIPEWORK - 1 SET.
 COW CATCHER - 2 NOS.
 MAJOR PARTS OF UNDERFRAME ASSEMBLY
[ DRAWING No. – IB021-0317 & IB021-0380 ]

 HEADSTOCK ASSEMBLY. - 2 NOS.

 BOLSTAR ASSEMBLY [1 END] - 1 NO.
 BOLSTAR ASSEMBLY [2 END] - 1NO.
 CENTRAL UNDERFRAME ASSEMBLY. - 1 NO.
 SIDE SILL ASSEMBLY [ L.H. & R.H. ] -2
NOS.
 CENTRE SILL ASSEMBLY. - 1 NO.
 PLATE INFILL ASSEMBLY. -1
SET.
 MAJOR MACHINERY AND JIG & FIXTURE
REQUIRED FOR UNDERFRAME ASSEMBLY.

 PLANO MILLER MACHINE. [ Bed Size : 3.4m x 4.5m ]. - 1 No.

 PLASMA CUTTING MACHINE [ Up to 60 Thk. plate cutting capacity ]. - 1 No.
 WELDING MACHINE
 CRANE / EOT [ 50T Lifting capacity ]. - 2 Nos.
 LEVEL BED [ made up of 300 beam over a top plate 32 mm Thk., Size : 3.2m x 22 m ]. - 1 No.
 LEVEL BED [ made up of 500 beam over a top plate 25 mm Thk., Size : 3.2m x 4 m ]. - 1 No.
 HYDRAULIC JACK [ 50T, Lift 500mm ] - 4 Nos.
 COUNTER WEIGHT [ 3T, made up concrete block with corner reinforced with angle ]. - 6 Nos.
 UNDER FRAME ROTATING JIG [ Trunnion with stand at both end + clamping attachment at center ].
 SEQUENCE OF OPERATION INVOLVED IN
UNDER FRAME ASSEMBLY.

 Raw material testing.

 Fit up of individual major parts of under frame assembly.
 Offer inspection and welding, major parts of under frame assembly.
 Fit up of under frame assembly.
 Maintain camber 17 mm as per CAMBER DIAGRAM with the help of counter weight and jack.
 Offer inspection and welding, top of under frame assembly.
 Rotating of under frame assembly with the help of rotating jig and fit up of secondary members.
 Offer inspection and welding, bottom of under frame assembly.
 Please Note : after fit up and after welding inspection to be offered, also welding procedure & test to be carried out in
accordance with AS1554-1991 SP.
 CAB ASSEMBLY.

 Major parts of cab assembly is made up of 3.15 mm Thk. Sheet.

 Jig fixture to be use to maintain its formation, dimension and
welding.
 Both CAB Structures to be installed above Underframe and
welding to be done as indicated on Drg. No. IB081-00313.
 To speed up manufacturing both CAB Structure Assembly may
be brought out from outside.
 Weight of each cab assembly is 1976.3 kg.
 BODY SIDE WALL.

 Major parts of SIDE Wall Assembly is made up of 6 mm Thk. plate

and 75 & 200 channel.
 Before installing both SIDE Wall above the Underframe the 17 mm
camber of Side Sill to be checked as per CAMBER DIAGRAM and a
check record sheet to be maintained.
 Both SIDE Wall Assembly's are to be installed at the same time to
ensure ROOF Hatch landing area flatness of 1mm per meter in any
direction.
 After fit up and after welding inspection to be offered.
 Weight of each cab assembly is ______ kg.
 ROOF HATCH ASSEMBLY.

 Major parts of Roof Hatch assembly is made up of 3.15 mm

Thk. Sheet and formed channel.
 Jig fixture to be use to maintain its formation, dimension and
welding.
 ROOF Hatch Assembly to be installed over both SIDE Wall.
ROOF Hatch landing area flatness of 1mm per meter in any
direction to be maintained.
 To speed up manufacturing ROOF Hatch Assembly may be
brought out from outside.
 Weight of ROOF Hatch Assembly is ______ kg.
 DRIVER DECK ASSEMBLY.

 Major parts of DRIVER DECK Assembly is made up of

1.6 mm Thk. Sheet.
 Jig fixture to be use to maintain its formation, dimension
and welding.
 Both DRIVER DECK Assembly to be installed inside the
both CAB Assembly.
 To speed up manufacturing both DRIVER DECK
Assembly may be brought out from outside.
 Weight of each cab assembly is _____ kg.
INFORMATION ABOUT COSTING

 BED WEIGHT : 18T.

 U/F ROTATING JIG WEIGHT : 7T.
 TOTAL 14 NOS. SMALL JIG & FIXTURE COST : 1.3 Lacs [ approx. ]
 TOTAL MIG WELDING WIRE REQD. : 2500 kg [ approx.]
 PAINTING & PIPE WORK LABOUR COST : 1.2 Lacs [ approx. ]
 LABOUR COST FOR MANUFACTURING : 16 Lacs [ approx. ]
 SPECIAL TRUCK REQD. FOR DESPATCH.