1. INTRODUCTION TO D.L.

W
Diesel Locomotive Works (DLW) is 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 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 general 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.

Fig 1

2. INTRODUCTION TO LOCOMOTIVE
A diesel engine can be either two-stroke or four-stroke and, except for its ignition, is much like any other internal combustion engine. It is one of three types- V, vertical inline, or horizontal (depending on the arrangement of its cylinders). The fuel system includes the fuel tank, fuel and ignition pumps, filters, injection nozzle, and emergency fuel cut-off valve. The fuel tank has baffle plates to prevent surging and a pit to catch sediment so that it can be drained out. In some locomotives, the fuel tank is above the pump and fuel enters the pump by gravity. In others, fuel is pumped from the tank into the main pump by an auxiliary pump. The fuel pump creates the injection pressure and determines the amount of fuel injected into the cylinders by the injectors. In an engine with a water-cooling system, water is run through water jackets between the cylinders and cylinder liners. The water is directed through a radiator to cool it. Louvers on the front of the radiator can be opened and closed to regulate the heat escaping from it. Occasionally, an engine is designed so that the pistons are cooled also by their lubricating oil. When this is done, a special oil radiator, with its own cooling fan, is provided in addition to the water cooling radiator. Lubricating oil should have some detergent properties so that contaminating materials can be kept in suspension and filtered out by strainers, made of gauze, steel wool, or closely spaced plates. Brakes for a locomotive can be the kind that controls the locomotive, the train, or both. Air pressure for the brakes is supplied by a compressor. The weight of the locomotive is carried by the trucks, which also absorb lateral thrusts and oppose the tilting tendency. A truck is made of frames, wheels, axles, journals and journal boxes, bolsters, springs, bearings, and brake rigging. Most locomotives are equipped with chains to limit the swing of the trucks in case of derailment.

Locomotives larger than 40 tons use four-wheel rigid trucks, four-wheel swing bolster trucks, or six-wheel swing bolster trucks. Accessories supported by the locomotive engine include a bell, horn, speed recorder, wipers, sanding system, temperature controls, and engine and cab heaters. Measures of electrical pressure, resistance, and quantity are called volts, ohms, and amperes. A volt is the unit of pressure leaving the generator or battery; an ohm is a unit of resistance; and an ampere is the unit used to measure power available to the receiving mechanism, such as one of the traction motors. Ohm's law states the relationship between these: current equals voltage divided by resistance. Voltage is measured by a voltmeter and amperage by an ammeter. Wiring diagrams, using lines and standardized symbols and abbreviations, are used in tracing circuits and locating troubles on diesel-electric locomotives. Wiring in the electric system is built to carry a specific load of current; current heavier than that specified is called an overload. Since an overload in the wiring can harm equipment, fuses and circuit breakers are provided to break the circuit before damage occurs Mechanical energy can be changed into electrical energy, or electrical into mechanical, by a dynamo. If the mechanical energy is changed into electrical, the dynamo is called a generator; if the electrical energy is changed into mechanical, the dynamo is a motor. A generator can be either the alternating current or the direct-current type. Current is set up in the generator's armature coil whenever the coil cuts across the lines of magnetic force between the generator's poles. With an alternating-current generator, the current flows through the coil first in one direction then the other unless the generator has a communicator to turn the alternating current into a direct current. If a generator has many coils, connected to form a closed circuit, a direct current is supplied. Direct current generator coils can be connected in series, in shunt, or in a combination of series and shunt. Like a generator, a motor can also be connected in shunt or in series.

Because of the locomotive's size and weight, gears large enough to control it would be

too large and bulky to be practical. Mechanical gear transmission of power to the wheels is therefore replaced by electrical transmission. To change the mechanical force from the engine into electrical power, an alternator is operated by the engine's crankshaft. The output of the alternator is rectified with the help of static rectifiers and cables transmit the power to traction motors and the traction motors turn the wheels. Traction motors are series-wound, direct current motors and are provided with a shunt. Their function is to convert electrical energy from the generator into mechanical force to turn the locomotive wheels.

Electrical circuits in the locomotive are connected in series, in parallel, or in seriesparallel, a combination of the two. Circuits are opened and closed by contactors, operated either by compressed air in heavy circuits, or by current from the battery in circuits where the current is low. Auxiliary switches to control the connecting or breaking of circuits are called interlocks. A relay is a device that changes connections in one part of a circuit in response to changes taking place in another part. Changing traction motors from series connection to series-parallel or parallel connection is known as transition. It can be done by connecting the motors in parallel or by shunting off part of the current drawn into the circuit, forcing more current to be drawn from the generator. A traction motor cutout switch is used to take the motors out of circuit if there is an electrical failure.

In dynamic braking, the locomotive's wheels are used to drive the traction motors, which acting like generators, slow the locomotive's speed without causing wear of the wheels. When brakes are applied, a pneumatic switch stops the engine, stops the fuel pump, and turns on indicating lights.

3. Brief 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 locomotives. to manufacture state-of-the-art high traction AC-AC diesel

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-ValueTechnology 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.

3.1 SALIENT FEATURES

Annual production capacity Annual turn-over (Rs) Total number of staff Workshop land Township area Covered area in shops Covered area of other service buildings Electrical power requirement (Average maximum demand) Electrical energy consumption (units/year) Stand by power generation capacity 19.8 million 3000 KW 125 Locomotives 5000 million 7223 89 Hectares 211 Hectares 86300 Sq.m 73700 Sq.m 3468 KVA

4. Classification of Indian locomotives In India, locomotives are classified according to their track gauge, motive power, the work they are suited for and their power or model number. The class name includes this information about the locomotive. It comprises 4 or 5 letters. The first letter denotes the track gauge. The second letter denotes their motive power (Diesel or Electric). The third letter denotes the kind of traffic they are suited for(goods, passenger, mixed or shunting). The fourth letter used to denote locomotives' chronological model number. However, from 2002 a new classification scheme has been adopted. Under this system, for newer diesel locomotives, the fourth letter will denote their horsepower range. Electric locomotives don't come under this scheme and even all diesel locos aren't covered. For them this letter denotes their model number as usual. With the new scheme for classifying diesel locomotives (as mentioned above) the fifth item is a letter that further refines the horsepower indication in 100 hp increments: 'A' for 100 hp, 'B' for 200 hp, 'C' for 300 hp, etc. Thus a WDM-3A refers to a 3100 hp loco, while a WDM-3F would be a 3600hp loco.

5. 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 costomer requirments and other products. the product range avilable is as under. : WDG4 WDP4 WDG3D controller Locomotive. WDM3C WDM3A WDP3A WDG3A WDM2 WDP1 WDM7 WDM6 YDM4 Locomotive. EXPORT LOCO Locomotive. Diesel Generating Sets 800 KW to 2500 KW 2300 HP AC/DC Meter Gauge/Cape gauge Mixed Traffic 3300 HP AC/DC Broad Broad Gauge Mixed Traffic Locomotive. 3100 HP AC/DC Broad Gauge Mixed Traffic Locomotive. 3100 HP AC/DC Broad Gauge High Speed Passenger Locomotive. 3100 HP AC/DC Broad Gauge Freight Locomotive. 2600 HP AC/DC Broad Gauge Mixed Traffic Locomotive. 2300 HP AC/DC Broad Gauge Intercity Express Locomotive. 2150 HP DC/DC Broad Gauge Mixed Traffic Locomotive. 1350 HP DC/DC Broad Gauge Mixed Traffic Locomotive. 1350 HP AC/DC & DC/DC Broad Gauge Mixed traffic 4000 HP AC/AC Frieght traffic Locomotive 4000 HPAC/AC Broad Gauge High Speed Locomotive 3400 HP AC/AC Broad Gauge Mixed Traffic Micro-Processor

Spare Parts fot engines, locomotives and generating set. 5.1 The classification syntaxes:

Locos, except the older steam ones, have classification codes that identify them. This code is of the form [ gauge ][ power ][load ][ series ][ sub type ][ suffix ] 5.1.a The first letter (gauge) 8

W-broad gauge Y-meter gauge Z-narrow gauge(2.5ft) N-narrow gauge(2ft) 5.1.b The second letter (motive power) D- diesel C- DC electric (can run under DC traction only) A- AC electric (can run under AC traction only) CA- both AC and DC (can run under both AC and DC traction),CA is considered a single letter. B-battery electric locomotive (rare) 5.1.c The third letter (job type) G-goods P-passenger M-mixed, both goods and passenger S-used for shunting (also known as switching engines or switchers in united states and some other countries) U-electric multiple (used as commuters in city suburbs) R-railcars

5.1.d 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. 5.1.e The fifth letter (subtype)An optional letter or number that indicates some smaller variations in the basic model. For example 1 in WDM3A: W means broad gauge D means diesel motive power M means suitable for mixed (for both good and passengers) service 3A means the locomotive power is 3100hp, (3 stands for 3000hp, A denotes 100hp more). Example 2 In WAP5 W means broad gauge A means AC electric traction motive power P means suitable for passenger service 5 denotes that this locomotive is chronologically the fifth electric locomotive model used by the railway for passenger service.

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6. Weld shop
This shop deals with various welding process, equipment and techniques. Some of the welding processes are: 6.1 GTAW WeldingGas Tungsten Arc Welding (GTAW) is frequently referred to as TIG welding. TIG welding is a commonly used high quality welding process. TIG welding has become a popular choice of welding processes when high quality, precision welding is required. In TIG welding an arc is formed between a nonconsumable tungsten electrode and the metal being welded. Gas is fed through the torch to shield the electrode and molten weld pool. If filler wire is used, it is added to the weld pool separately. Fig 2

6.2 MIG WeldingGas Metal Arc Welding (GMAW) is frequently referred to as MIG welding. MIG welding is a commonly used high deposition rate welding process. Wire is continuously fed from a spool. MIG welding is therefore referred to as a semiautomatic welding process.

Fig 3

6.3 Resistance WeldingResistance Spot Welding (RSW), Resistance Seam Welding (RSEW), and Projection Welding (PW) are commonly used resistance welding processes. Resistance welding uses the application of electric current and mechanical pressure to create a weld between two pieces of metal. Weld electrodes conduct the electric current to the two pieces of metal as they are forged together.

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The welding cycle must first develop sufficient heat to raise a small volume of metal to the molten state. This metal then cools while under pressure until it has adequate strength to hold the parts together. The current density and pressure must be sufficient to produce a weld nugget, but not so high as to expel molten metal from the weld zone.

Fig 4 6.4 Arc weldingArc welding is a type of welding that uses a welding power supply to create an electric arc between an electrode and the base material to melt the metals at the welding point. They can use either direct (DC) or alternating (AC) current, and consumable or nonconsumable electrodes. The welding region is usually protected by some type of shielding gas, vapor, and/or slag.

Fig 5 6.5 Spot welding (RSW)It is a process in which contacting metal surfaces are joined by the heat obtained from resistance to electric current flow. Work-pieces are held together under pressure exerted by 12

electrodes. Typically the sheets are in the 0.5 to 3 mm (0.020 to 0.12 in) thickness range. The process uses two shaped copper alloy electrodes to concentrate welding current into a small "spot" and to simultaneously clamp the sheets together. Forcing a large current through the spot will melt the metal and form the weld. The attractive feature of spot welding is a lot of energy can be delivered to the spot in a very short time (approximately ten milliseconds). That permits the welding to occur without excessive heating to the rest of the sheet.

Fig 6

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7. Machine shop
7.1 Lathe machine-

Fig 7 When a work piece is fixed between the headstock and the tail-stock, it is said to be "between centers". When a work piece is supported at both ends, it is more stable, and more force may be applied to the work piece, via tools, at a right angle to the axis of rotation, without fear that the workpiece may break loose. When a workpiece is fixed only to the spindle at the headstock end, the work is said to be "face work". When a workpiece is supported in this manner, less force may be applied to the workpiece, via tools, at a right angle to the axis of rotation, lest the workpiece rip free. Thus, most work must be done axially, towards the headstock, or at right angles, but gently. When a workpiece is mounted with a certain axis of rotation, worked, then remounted with a new axis of rotation, this is referred to as "eccentric turning" or "multi-axis turning". The result is that various cross sections of the workpiece are rotationally symmetric, but the workpiece as a whole is not rotationally symmetric. This technique is used for camshafts, various types of chair legs.

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7.2 Milling machine-

Fig 8 The choice between vertical and horizontal spindle orientation in milling machine design usually hinges on the shape and size of a workpiece and the number of sides of the workpiece that require machining. Work in which the spindle's axial movement is normal to one plane, with an endmill as the cutter, lends itself to a vertical mill, where the operator can stand before the machine and have easy access to the cutting action by looking down upon it. Thus vertical mills are most favored for diesinking work (machining a mold into a block of metal). Heavier and longer workpieces lend themselves to placement on the table of a horizontal mill. Prior to numerical control, horizontal milling machines evolved first, because they evolved by putting milling tables under lathe-like headstocks. Vertical mills appeared in subsequent decades, and accessories in the form of add-on heads to change horizontal mills to vertical mills (and later vice versa) have been commonly used. Even in the CNC era, a heavy workpiece needing machining on multiple sides lends itself to a horizontal machining center, while diesinking lends itself to a vertical one.

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7.3 Shaper machine-

Fig 9 A shaper is a type of machine tool that uses linear relative motion between the workpiece and a single-point cutting tool to machine a linear toolpath. Its cut is analogous to that of a lathe, except that it is (archetypally) linear instead of helical. (Adding axes of motion can yield helical toolpaths, as also done in helical planing.) A shaper is analogous to a planer, but smaller, and with the cutter riding a ram that moves above a stationary workpiece, rather than the entire workpiece moving beneath the cutter. The ram is moved back and forth typically by a crank inside the column; hydraulically actuated shapers also exist. Typ, contour and traveling head. The horizontal arrangement is the most common. Vertical shapers are generally fitted with a rotary table to enable curved surfaces to be machined (same idea as in helical planing). The vertical shaper is essentially the same thing as a slotter (slotting machine), although technically a distinction can be made if one defines a true vertical shaper as a machine whose slide can be moved from the vertical. A slotter is fixed in the vertical plane. Small shapers have been successfully made to operate by hand power. As size increases, the mass of the machine and its power requirements increase, and it becomes necessary to use a motor or other supply of mechanical power. This motor drives a mechanical arrangement (using a pinion gear, bull gear, and crank, or a chain over sprockets) or a hydraulic motor that supplies the necessary movement via hydraulic cylinders.

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7.4 Bench grinder-

Fig 10 A bench grinder is a type of benchtop grinding machine used to drive abrasive wheels. A pedestal grinder is a larger version of a bench grinder that is mounted on a pedestal, which is bolted to the floor. These types of grinders are commonly used to hand grind cutting tools and perform other rough grinding.[1] Depending on the grade of the grinding wheel it may be used for sharpening cutting tools such aslathe tools or drill bits. Alternatively it may be used to roughly shape metal prior to welding or fitting. A wire brush wheel or buffing wheels can be interchanged with the grinding wheels in order to clean or polish work-pieces. Grinding wheels designed for steel should not be used for grinding softer metals, like aluminium. The soft metal gets lodged in the pores of the wheel and expand with the heat of grinding. This can dislodge pieces of the grinding wheel. 7.5 Planer machine-

Fig 11 A planer is a type of metalworking machine tool that uses linear relative motion between the workpiece and a single-point cutting tool to machine a linear toolpath. Its cut is analogous to that of a lathe, except that it is (archetypally) linear instead of helical. (Adding axes of motion can yield helical toolpaths; see "Helical planing" below.) A planer is analogous to a shaper, but larger, and with the entire workpiece moving on a table beneath the cutter, instead of the cutter riding a ram that moves above a stationary workpiece. The table is moved back and forth on the bed beneath the cutting head either by mechanical means, such as a rack and pinion drive or aleadscrew, or by a hydraulic cylinder. 17

7.6 Drilling machine-

Fig 12 A drilling rig is a machine which creates holes in the ground. Drilling rigs can be massive structures housing equipment used to drill water wells, oil wells, or natural gas extraction wells, or they can be small enough to be moved manually by one person. They sample subsurface mineral deposits, test rock, soil and groundwater physical properties, and also can be used to install sub-surface fabrications, such as underground utilities, instrumentation, tunnels or wells. Drilling rigs can be mobile equipment mounted on trucks, tracks or trailers, or more permanent land or marine-based structures (such as oil platforms, commonly called 'offshore oil rigs' even if they don't contain a drilling rig).

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8. Engine testing
Engine Testing is a unique, well-organized and comprehensive collection of the different aspects of engine and vehicle testing equipment and infrastructure for anyone involved in facility design and management, physical testing and the maintenance, upgrading and trouble shooting of testing equipment. Fig 13 Fig 14

8.1 Types of testing: 8.1.a Lubricating oil testing Lubrication is done for better performance of the engine parts. testing is done by checking the circulation of lubricant oil. For rotating parts checking is done by seeing the returning path of the oil i.e. checking not only the forward path but also the returning path. RR40 is used as lubricating oil.

8.1.b Water testing Water acts as a coolant for moving part of the engine because constant movement or rotation causes various parts to heat up and water working as coolant cooled down the concerned part. 8.1.c Load testingFor load testing electrical load is provided to the engine. If there is any abnormal sound then the engine is again tested for lubrication so that any flaw which is there can be removed. For example:- DWG2 DWG2 class 3100 hp diesel electric locomotive AC-DC transmission, powdered with D.L.W. built 16 cylinder ALCO251C diesel engines is exclusively designed for heavy freight service.

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 High adhesion two stage suspension design trucks minimize weight transfer and provide a higher traction effort and excellent riding quality. WDG2 is popular for the low and easy maintenance at extended periods, reduced noise and exhaust emission, fuel saving safe operation. General characteristics Installed Power input to traction under site condition Gauge Principle dimension Locomotive weight Nominal axel load Wheel diameter Maximum starting tractive effort Fuel tank capacity Max speed Basic featuresDiesel engine Model 16 cylinder ALCO251C , DLW built Medium speed, 4 strokes Fuel efficient 8.2 Engine test operation sequence Base inspection under screen and fitting over screen. Water circulation. Lube oil filling and check deflection crank shaft. Lube oil circulation. Pre run on no load 3 to 5 times of duration 10 to 30 min each 400 rpm. 20 123000 kg 20500 kg 1092 mm 37884 kg 6000 liters 100 km/hr 3100 hp 2750 hp 1676 mm

 Intermediate runs 12 runs of 30 min duration each from 400 to 1000 rpm. Check over speed trip of recheck 3 times. Check bake in nozzles and set tapped clearance. Inspection before fist hour performance. First hour performance on full load. Base inspection. Second hour performance on full load. Attend defects of first hour performance. Final base inspection. Check engine deficiencies. Engine clearance.

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9. LOCOMOTIVE TESTING SHOP

Fig 15 It is the shop where the final testing of the engine is performed before the engine is dispatched for use by the Indian railways. The important electrical in spections and tests performed are : FIR Impulse Insulation Registering (IR)High Potential Test Battery Connection Digital I/O checking (for microprocessor control unit)Fuel pressure adjustment Engine Cranking Auxiliary Generator Check AC Voltage Check Temperature switch check Load cable connection and load test Loco Normalisation test (In which load cable is disconnected)Traction Motor boot application DM Boot application Track test and dynamic brake checking Running operation Brake safety devices Static air pressure (SAP) test for motor cooling Rotary machine in section Locomotive Brake Systems a) Charging b) Pressure gauges c) Compressor governor d) Main Reservoir Leakage e) Reservoir Check Valve f) Brake Pipe Leakage g) Air Compressor Check h) Auto brake valve i) Brake Pipe Maintaining Feature j) Independent Brake k) Cut off Valve l) Lead or Trail Selector m) Dynamic Interlock n) Brake Cylinder Leakage o) Brake-in-two p) Main Reservoir Safety Valve q) Vigilance Control r) Remote Control Locomotives

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9.1 AN OUTLINE OF LOCO TESTING Electric locomotives must be tested at normal line voltage. A general outline of loco testing is as mentioned below. However, its a mere picture of whats actually done. The actual no. of tests is very large and it was out of the scope of the training. 1. Engine is brought to the shop LTS 2. Its in spected properly for any visible locomotive errors. 3. Fuel Oil tank is tested for leakage. 4. This is done by filling it with water. 5. Indon solution (0.68 kg in 1000L of water) is filled in expansion tank 6. Lube oil filling 7. Air compressor/expresser setting is tested 8. Crank shaft delection and lube oil circulation tests are performed. 9. Initial working and temperature checking is done: Lube oil pressure: 4-5 kg/cmFuel oil pressure: 3.5-4.5 kg/cm 10. Load Test: All load connections are made Crank case vacuum is checked U tube water manometer is used to measure the pressure of fuel oil. At full load, a) Lube oil pressure: 6.5-7.5 kg/cm b) Fuel oil pressure: 2.8 kg/cm c) Turbo Discharge pressure should be the same both in driver cab gauge and mercury manometer in testing centre. d) Booster Air pressure: 1.6-1.6-1.79 kg/cm for 46"-52" DWM2 loco1.7-9.0-1.79 kg/cm for 52"-59" DWDG2 loco e) Temperature of engine cooling water is 80C 11. Air Brake tests: The Independent and auto brakes as well as the emergency brakes are tested. Also the brake pipe and brake cylinders are tested for leakages. At the same time compressors are tested either by orifice test or by the time taken to charge the main reservoir from 0 kPa to 550.

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References

1) Workshop technology by Hazara &Chaudhary 2) Production technology by P.C Sharma 3) Study material provided by Techanical Training Centre in Diesel Locomotive Works, Varanasi 4) Workshop technology by S.K Garg

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