DLW Vocational Training Report,
DLW Vocational Training Report.pdf
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Sample of Report
ACKNOWLEDGEMENT
I would sincerely like to thank the employees and the officers of DLW, VARANASI for their help and support during the vocational training. Despite their busy schedules, they took time out for us and explained to us the various aspects of the working of the plant from the production shops. I would sincerely like to thank Mr. Sudhir Sinha (CWI /TTC) and Mr. Ajay Kumar(JE/HWS), Mr. Vipin Srivastava(JE/HWS), Mr. Arvind Kumar(JE/HMS), Er. Ravi Gupta(SSE/HMS) who was instrumental in arranging the vocational training at DLW Varanasi, and without thier help and guidance the training could not have materialize. I express my deep sense of gratitude to Mr. S.P.Singh (Principal, TTC) for given me such a great opportunity.5
A SUMMER FIELD TRAINING REPORT AT DIESEL LOCOMOTIVE WORKS VARANASI Submitted To Faculty Of Engineering And Technology, Gyan vihar school of enginee ring & Technology, jaipur In partial fulfillment of the requirement for the award of degree of BACHELOR OF TECHNOLOGY IN MECHANICAL ENGINEERING Submitted To:- Submitted By:- Mr. Harish Arora Gagan Kumar Jha (Associate Professor) ME10401307234 Batch: 2013-17
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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 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 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 final year mechanical and this report is written on the basis of practical knowledge acquired by me during the period of practical training taken at Diesel Locomotive Works, Varanasi.7
CONTENTS
[1].Introduction to DLW……………………………………… 9-12 Brief history……………………………………………… 10
Salient feature…………………………………………..... 11
Types of Locomotives produce…………………………... 12
Product of DLW………………………………………….. 12
[2]. Diesel Locomotive Technology.........................................13-18
The Diesel Locomotive…………………………………....13
Diesel Engine……………………………………………...13
Main Alternator……………………………………………14
Auxiliary Alternator……………………………………….14
Motor Blower……………………………………………...14
Air Intakes…………………………………………………15
Rectifiers/Inventers……………………………………..…15
Electronic Controls………………………………………....16
Control Stand……………………………………………...16
Diesel- Electric Locomotives……………………………..17
Alternators………………………………………………...17
Governor…………………………………………………..18
[3].Offices……………………………………………………….19-20
Design office………………………………………………19
Material Control office…………………………………….19
Store office…………………………………………………20
Account office……………………………………………...20
Panning office……………………………………………...20
Progress office……………………………………………...20
[4].Production Shop………………………………………………21
Blok Division………………………………………………...21
Engine Division……………………………………………....21
Loco Division………………………………………………...21
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[5]. Heavy Welding Shop………………………………………..27 [6]. Heavy Machine Shop……………………………………….30 [7]. Heat Treatment Shop………………………………………32 [8]. Engine Erection Shop………………………………………35 [9]. Engine Test Shop…………………………………………..38 [10]. Locomotive Frame Shop………………………………….40 [11]. Locomotive Assembly Shop……………………………....42 [12]. Locomotive Test Shop…………………………………….56 [13]. Conclusion…………………………………………………58 [14]. Suggestions………………………………………………...59 [15]. Bibliography………………………………………………60
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INTRODUCTION
TO DLW Diesel Locomotive Works (DLW) is a production unit under the ministry of railways. This 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. Subsequently a contract for transfer of technology of 4000 HP Microprocessor Controlled AC/AC Freight (GT 46 MAC) / passenger (GT 46 PAC) locomotives and family of 710 engines has been signed with electro motive division of GENERL MOTORS of USA for manufacture in DLW. The production of these locomotives has now started and thus DLW is the only manufacturers of Diesel Electric Locomotives with both ALCO and General Motors technologies in the world.
10Brief History:
• Set up in 1961 as a green-field project in technical collaboration with ALCO/USA to Manufacture Diesel Electric Locomotives• First locomotive rolled out and dedicated to nation in January, 1964.
• Transfer-of-Technology agreement signed with General Motors/ USA in October, 95 to manufacture state-of-the-art high traction AC-AC diesel locomotives.
• A flagship company of Indian Railways offering complete range of flanking products in its area of operation.
• State-of-the art Design and Manufacturing facility to manufacture more than 150 locomotives per annum with wide range of related products viz. components and sub-assemblies.
• Unbeatable trail-blazing track record in providing cost-effective, eco-friendly and reliable solutions to ever-increasing transportation needs for over three decades.
• Fully geared to meet specific transportation needs by putting Price-Value-Technology equation perfectly right.
• A large base of delighted customers among many countries viz. Sri Lanka, Malaysia, Vietnam, Bangladesh, Tanzania to name a few, bearing testimony to product leadership in its category.
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SALIENT FEATURES:
Annual production capacity125 Locomotives
Annual turn-over (Rs)
5000 million
Total number of staff
7223
Workshop land
89 Hectares
Township area
211 Hectares
Covered area in shops
86300 𝑚𝑚2
Covered area of other service buildings
73700 𝑚𝑚2
Electrical power requirement (Average maximum demand)
3468 KVA
Electrical energy consumption (units/year)
19.8 million
Standby power generation capacity
3000 KW
TYPES OF LOCOMOTIVES PRODUCED AT DLW:
• The First Letter Gauge
1. W- Indian broad gauge
2. Y- meter gauge
3. Z- narrow gauge(2.5 ft)
4. N- narrow gauge (2 ft)
• The second letter (motive power)
1. D- Diesel
2. C- DC electric (can run under DC traction only)
3. A- AC electric (can run under AC traction only)
4. CA- Both DC and AC (can run under both AC and DC tractions)
5. B- Battery electric locomotive (rare)
• The third letter (load type)
1. G-goods
2. P-passenger
3. M-mixed traffic ; both goods and passenger
4. S-Used for shunting
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5. U-Electric multiple units (E.M.U.)
6. R-Railcars
• THE fourth letter (series)
The series digit identifies the horsepower range of the locomotive.
Example for the series letter ‘3’ means that the locomotive has power over 3000 hp but less than 4000 hp.
• The fifth letter (subtype)
• an optional letter or number that indicates some smaller variations in the basic model.
• For ex: ‘A’ for 100 hp,
‘B’ for 200 hp and so on…….. PRODUCT OF DLW: DLW 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.
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• 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.
Diese ese l Locomotive Tehnology
The Diesel Locomotive
The modern diesel locomotive is a self contained version of the electric locomotive. Like the electric locomotive, it has electric drive, in the form of traction motors driving the axles and controlled with electronic controls. It also has many of the same auxiliary systems for cooling, lighting, heating, braking and hotel power (if required) for the train. It can operate over the same routes (usually) and can be operated by the same drivers. It differs principally in that it carries its own generating station around with it, instead of being connected to a remote generating station through overhead wires or a third rail. The generating station consists of a large diesel engine coupled to an alternator producing the necessary electricity. A fuel tank is also essential. It is interesting to note that the modern diesel locomotive produces about 35% of the power of a electric locomotive of similar weight.
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Diesel Engine
This is the main power source for the locomotive. It comprises a large cylinder block, with the cylinders arranged in a straight line or in a V. The engine rotates the drive shaft at up to 1,000 rpm and this drives the various items needed to power the locomotive. As the transmission is electric, the engine is used as the power source for the electricity generator or alternator, as it is called nowadays.
Main Alternator
The diesel engine drives the main alternator which provides the power to move the train. The alternator generates AC electricity which is used to provide power for the traction motors mounted on the trucks (bogies). In older locomotives, the alternator was a DC machine, called a generator. It produced direct current which was used to provide power for DC traction motors. Many of these machines are still in regular use. The next development was the replacement of the generator by the alternator but still using DC traction motors. The AC output is rectified to give the DC required for the motors. For more details on AC and DC traction, see the Electronic Power.
Auxiliary Alternator
Locomotives used to operate passenger trains are equipped with an auxiliary alternator. This provides AC power for lighting, heating, air conditioning, dining facilities etc. on the train. The output is transmitted along the train through an auxiliary power line. In the US, it is known as "head end power" or "hotel power". In the UK, air conditioned passenger coaches get what is called electric train supply (ETS) from the auxiliary alternator.
Motor Blower
The diesel engine also drives a motor blower. As its name suggests, the motor blower provides air which is blown over the traction motors to keep them cool during periods of heavy work. The blower is mounted inside the locomotive body but the motors are on the trucks, so the blower output is connected to
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each of the motors through flexible ducting. The blower output also cools the alternators. Some designs have separate blowers for the group of motors on each truck and others for the alternators. Whatever the arrangement, a modern locomotive has a complex air management system which monitors the temperature of the various rotating machines in the locomotive and adjusts the flow of air accordingly.
Air Intakes
The air for cooling the locomotive's motors is drawn in from outside the locomotive. It has to be filtered to remove dust and other impurities and its flow regulated by temperature, both inside and outside the locomotive. The air management system has to take account of the wide range of temperatures from the possible +40°C of summer to the possible -40°C of winter.
Rectifiers/Inverters
The output from the main alternator is AC but it can be used in a locomotive with either DC or AC traction motors. DC motors were the traditional type used for many years but, in the last 10 years, AC motors have become standard for new locomotives. They are cheaper to build and cost less to maintain and, with electronic management can be very finely controlled. To see more on the difference between DC and AC traction technology. To convert the AC output from the main alternator to DC, rectifiers are required. If the motors are DC, the output from the rectifiers is used directly. If the motors are AC, the DC output from the rectifiers is converted to 3-phase AC for the traction motors.
In the US, there are some variations in how the inverters
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