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Introduction to DMW

DMW was setup in 1981 with the assistance of World bank. Components manufacturing started in 1986. Production started for first time in carbon brush shop in January1986 It has two phases :
Phase 1: It has production shops Phase 2: It has rebuilding shops

Objective of DMW
Manufacturing and supply of high quality components and spares. Remanufacture of critical assemblies. Rebuilding locomotives and Power Pack. Incorporating latest technological up gradations. To enhance the performance of diesel locomotive.









Flow chart of Diesel Loco Rebuilding

Loco Testing Re-cabling, re-piping, brakes and loco assy Under frame cleaning and repairs Loco Stripping

Bogie assy and testing Power pack assy and testing

Frame repairs and furnishing Component reclamation and Engine Assy


Power pack

Engine block re-building Magnet frame reclamation

Engine Block

Rewinding of TMs Rewinding of TG

Traction motors

Traction Generator

Light Machine Shop

It has more than 70 CNC machines. It produces more than 250 components. It has the following main sections:
i. ii. iii. iv. Gear section. Cam shaft section. Connecting rod section. CNC turning section.

Heavy Machine Shop

Complete re-treatment of engine blocks. Re-treatment of magnet frames of traction motors. Conversion of magnet frames of 2600 HP loco to suit 3100/3300 HP locos.

Cylinder Liner Shop

Various important processes at CLS are: Cast iron honing Vapour cleaning Grit blasting Chrome plating Diamond honing

Power Pack Shop

Dismantling, reconditioning and assembly of power pack. Load testing, specific fuel consumption testing and other type of testing It has following main sections:
Striping section Reconditioning section Turbo supercharger section Governor room Test bed

Bogie Shop
Bogie is a main assembly of a diesel engine carrying its frame, wheel and axle assembly, various springs; traction motor etc.

Loco Rebuilding Shop

Water test of air dust cleaner Renewal of air filter housing and oil bath filter Replacement of radiator and radiator fan bearing Replacement of all gauges Renewal of water strips & rubber hoses

Designation of Diesel Locomotives

This code is of the form(WDM3A) [gauge][power][load][series][subtype]
W = Broad Gauge Y = Meter Gauge Z = Narrow Gauge (2' 6") N = Narrow Gauge (2')
D = Diesel C = DC traction A = AC traction CA = Dual-power AC/DC traction B = Battery electric (rare)
M = Mixed Traffic P = Passenger G = Goods S = Shunting L = Light Duty (Light Passenger?) (no longer in use) U = Multiple Unit (EMU / DEMU). R = Railcar (see below)

The series digit identifies the horsepower range of the loco The subtype character further refines the horse power increment

Project Work
To study all the components mounted on Power Pack of diesel loco and explain complete mounting and testing procedure of power pack assembly. To note down all the rework done in power pack shop and quality improvement steps taken.

Power Pack of Diesel Loco

It is the power generating component . It has an engine block of 16 cylinders v shaped inline. The firing order of the cylinders is 1R-1L-4R4L-7R-7L-6R-6L-8R-8L-5R-5L-2R-2L-3R-3L Fuel injection takes place before 25 degrees before TDC.

Main components mounted on power pack of diesel loco.

There are approximately 500 components mounted on power pack. A few of important are as under: Connecting rod Crank shaft Cam shaft Cylinder liner Engine block Piston with rings Gudgeon pin After cooler Lube oil filter Fuel filter Traction alternator Governor Crank case exhauster motor Over speed trip

Engine block
It is received from HMS after complete retreatment.

Piston, cylinder liner, connecting rod

Piston is made by Federal Mogul Goetze limited Bangalore. Cylinder liner is made of cast iron alloy with chrome plating on inside. Connecting rod is made of alloy steel.

Crank Shaft and Cam Shaft

Crank shaft is imported from China and USA Modified cam shafts are used these days.

Oil Catcher and Oil Damper

A cast aluminum oil catcher is mounted on the cylinder block and base and surrounds the periphery of the cranks shaft flange oil slinger at the power take-off end of the engine. Oil damper absorbs the vibrations of crank shaft.

Other main components

Cylinder head FIP : Fuel Injection Pump Turbo Super Charger After Cooler OST : Over Speed Trip Water and Lube oil pump Traction Alternator Governor

Cooling process of components

Cylinder liner are cooled by circulating water around their periphery. Cooling of piston crown is done by lubricating oil.
Lube oil from main bearing goes to crank pin>big end>connecting rod>small end>gudgeon pin>piston crown.

Cylinder heads has cooling water jacket in which water is circulated.

Testing of various components in PPS

Hydraulic Testing of Engine block. Hydraulic Testing of Gudgeon pin. Hydraulic Testing of Cylinder head. Crack detection in connecting rod on Magna flux machine. Backlash testing of Water and Lube oil Pump. Testing of power pack

Testing of Power Pack

Check all the connection of water pipes, lube oil, fuel oil etc. Water and fuel oil are circulated and checked for leakages (if any) Pre lubrication must be done. Run the engine for five minutes. Check the engine base screen for any foreign material. Load the engine gradually.

System wise failure percentage of 2008-09

Major up-gradations
Fuel efficient kit
Savings 6-7% - Rs. 600-800 thousand per annum

Power enhancement from 2600 HP to 3300 HP

Benefits derived: 3 extra coaches earns Rs. 12 million per annum Better acceleration- Punctuality improves More AC coaches with high revenue can be attached Recorded increase of 8.9% in revenue during 01-02

Major up-gradations-contd. Retro up-gradation of Engine Block

Retro up-gradation of blocks for higher horse power ratings by providing extra stiffeners.

Stiffer Unit cam shaft

Power up-gradation and reduced maintenance time DCW the only unit manufacturing unit cam shafts

251+ cylinder heads

Improved water jacket design for better cooling

Super bowl pistons with 11.75:1 CR

Lower peak firing pressures- more life

Major up-gradations-contd. Conversion from DC-DC to AC-DC transmission and roller bearing suspension
Lesser maintenance and higher reliability

Micro-processor based governor

Maintenance free and higher fuel efficiency

Maintenance schedules Trip schedule: 7days to 30 days

Savings- 40 trips/320 hrs/Rs. 300 thousand/annum

First major schedule: 12 months to 24 months

Savings- 1/168 hrs/Rs. 150 thousand/annum

Further Up-gradations
Power enhancement to 3600 HP
Prototype engine success fully tested Adaptation of electrics under process

Micro-processor based propulsion control system

GE designed system for self diagnostics and in-built safety systems Prototype locos under trial

Variable fuel injection timing

Prototype engine success fully tested

Rework done in PPS

Lube oil strainer was not set because it was not aligned in vertical direction so gasket like material was fitted along the periphery of strainer and bracket

Rework was done on turbocharger support by enlarging and tapping due to its holes was out. Ovality (0.003) of 6th cylinder on right side crossed so cylinder was taken out from the block Rework was done on L.O.P. by enlarging all holes of location plate and L.O.P

Quality improvement steps taken in PPS

Modification in push rod assembly with pressed ends Use of 18mm FIP to provide more fuel. Improved FIP tube with auto Frettage
Increases fatigue strength Can bear high pulsating pressure