Académique Documents
Professionnel Documents
Culture Documents
at
BACHELOR OF TECHNOLOGY
(MECHANICAL ENGINEERING)
By
Shobhit Kushwaha
14BTMECH044
7th Semester
1
ACKNOWLEDGEMENT
I would sincerely like to thank the employee and the officers of DLW
VARANASI for their help and support during the vocational training. Despite
their busy schedule. They took time out for us and explained to us the various
I would sincerely like to thank all SSE/JE who has instrumental in arranging
the vocational training at DLW VARANASI, and without whose help and
2
PREFACE
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
student of third year mechanical and this report is written on the basis of
3
CONTENTS
Introduction to DLW
Conclusion
Bibliography
4
INTRODUCTION TO DLW
(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
locomotives and family of 710 engines has been signed with electro motive
production of these locomotives has now started and thus DLW is the only
5
BRIEF HISTORY-
locomotives.
than 150 locomotives per annum with wide range of related products viz.
6
SALIENT FEATURES-
7
PRODUCT OF DLW-
Controlled Locomotive.
Locomotive.
Traffic Locomotive.
8
Diesel Generating Sets 800 KW to 2500 KW
DESIGN OFFICE-
Prepare diag. of each part and sent to Material Control & inform timely in any
Prepared material list (ml) which consists diag. & qty. of each part and sent to
the ML, take Funds & vetting from Account department & then issue tenders,
Open Tenders & Purchase Order issued. After Receiving of Material inspection
Deptt and sent to Acct. Department for payment to firm. If material is not OK
9
PLANNING OFFICE- Prepare JPO, Monthly Production Program,
Issue Job card & other production Documents. Preparing DLW Budget & Sent
to Rly Board.
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.
PRODUCTION SHOPS-
1. Block Divisions
2. Engine Divisions
3. Loco Divisions
BLOCK DIVISION-
10
ENGINE DIVISION-
1. 5.Rotor Shop
LOCO DIVISION-
2. Pipe Shop
SERVICE SHOPS-
1. Maintenance Areas#1, 2, 3
2. Tool Room
11
PERSONNAL DEPARTMENT- Prepare payment of Staff, Leave Record,
12
Agreement with General Motors of USA for technology transfer to
in India;
past and many more in the pipeline; Supplied more than 400 locomotives
FUTURE PLANS-
electric locomotives;
13
TRUCK MACHINE SHOP
Truck Machine Shop deals with marking to truck frame. Axes boxes, spring seat
etc. & machining of as per these items, marking & machining of axel color
frame
14
MARKING & TRUCK MILLING SECTION-
This section deals with the marking of the truck frame and milling of truck
frame, Marking of axle boxes, Equalizers, spring seat, Brake Block and various
misc., items. These items marked as per drawing after marking, items moves to
machining. Truck Frame deals in the section with Horizontal machine and
Boring machine.
This section deals with various type of center lathe machine. The items are
finished in this section and sent to use in other shop is SMS, LFS etc. Such as
Fuel Bracket, Bolts, Pin etc. The operation done by this section Tapping,
This section has different types of turret lathe machine according to the
specification and maintains size. In these machine some for heavy duty and
some for light duty. The items is being machined in this section as hanger pin,
coupler pin, bracket lever, bolts & nuts, shafts and studs (extension shafts,
15
WHEEL AND AXLE MACHINING CENTER-
This section deals with machining of wheel & axle. Different types of machine
BG = 9.938 ± 0.01
BG = 8.188 ± 0.01
BG = 9.929 ± 000
BG = 9.180 ± 000
This section deals with wheel & Axle assembly, Lube oil, Lube Oil valve
This section deals with grinding of envier; different type of lever oil pans, brake
equalizer guide and other various items are used in TMS. Space welding is
being also in frame in track center pivot & tow oil pans used.
16
TRUCK ASSEMBLY SECTION-
pistons is used.
This section deals with assembly of traction motor with wheel & axle assembly
17
LOCO ASSEMBLY SHOP
In LAS, there are step by step process for the assembled the locomotive. There is a
sequence for assemble. In LAS Electrical control equipment is fitted and control cable
harnessing is undertaken. The complete locomotive is thus assembled before being sent
onwards for final testing and spray painting. Tested engines are received from Engine
Division. Similarly under frames are received from Loco frame shop and assembled trucks
from Truck machine shop. Super structure compartments and contractor compartment are
received from respective manufacturing and assembly shops of Vehicle Division. Important
alignments like crank shaft deflection, compressor alignment and Eddy Current clutch
OPERATION IN LAS-
Buffer assembly
Radiator setting
4. E n g i n e s e t t i n g
18
Compressor setting
6. Equipment assembly
7. D r i v e r s h e e t s e t t i n g
Damper assembly
19
HEAVY WELD SHOP
This shop mainly deals with the fabrication of engine block and base (B.G &
M.G) Turbo support. After cooler housing items the engine block is the
The spine being the most highly stressed item as we can say spine of the
cylinder block is made out of the piece bitted 5’’x 7’’ thickness confirming to IS
1895. The billet foundation plate and cylinder walls are built around the steel
forging saddles to form the air chambers which ensure the maximum rigidity for
aspects:
1. Inspection Standard.
2. Proper Materials.
5. Welfare of Staff.
20
SEQUENCE OF FABRICATION OF ENGINE BLOCK-
1. Setup saddles foundation plates and spine on special fixture and weld
top of spine.
9. Setup of top deck and lifter block for filament of eye bolt and tack weld.
14.Welding of the cam bearing and saddle with foundation rail bottom side.
21
18.Flame out counter of foundation plate to give relief clearance to free
19.Setup of side sheet and sub arc weld of side sheet and top deck.
21.Intermediate machining operation mills both and to layout for end plates
27.Short plats.
28.Final debarring.
22
ENGINE TEST SHOP
2. Water circulation
23
The engine test equipment area has been divided into section as follows:
This section will carry out the repairing and testing of pump and nozzles.
For starting the engine the main traction generator is run as a DC series motor
NOTE: The crank case inspection to be made after run test as piston and all
vital parts keep ending clean and free of all repair leaks and check all level and
24
INTERMEDIATE TEST-
25
RUN DOWN TEST-
It is done to check the air of the turbo charger or to ensure that the good amount
Water system.
LO system
FO system
Air system
slick.
26
9. Connection of all thermocouples.
10. LO circulations.
27
CONCLUSION
technology;
developing countries.
FUTURE PLANS-
locomotives;
28
3. To develop as an export hub for ALCO/ GM locos for Asian market;
29
BIBLIOGRAPHY
1. www.indianrailways.gov.in
2. Cris-dlw.cirs.org.in
3. www.irfca.org
30