ANINDUSTRIAL TRAINING PROJECT

OnRAILWAYS DIESEL ENGINE

Completed at

DIESEL LOCOMOTIVE SHEDTUGHLAKABAD, NEW DELHI

SubmittedIn partial Fulfilment of the Requirements

For the award of the Degree of

BACHELOR OF TECHNOLOGYin

MECHANICAL ENGINEERINGSubmitted by

BHEEKAM GAUR1313240044

20/06/2016 to 16/07/016(4 weeks)

GREATER NOIDA INSTITUTE OF TECHNOLOGYPLOT NO. 7, K.P.2, GREATER NOIDA, UP-201310

Affiliated to Dr. A.P.J. Abdul Kalam Technical University, Lucknow(Formerly known as Uttar Pradesh Technical University,

Lucknow)AUGUST-2016

AN

INDUSTRIAL TRAINING REPORT

AT

DIESEL LOCOMOTIVE SHED, TUGHLAKABAD, NEW DELHI

SubmittedIn partial Fulfilment of the Requirements

For the award of the Degree of

BACHELOR OF TECHNOLOGYin

MECHANICAL ENGINEERING

Submitted byBHEEKAM GAUR

1313240044

20/06/2016 to 16/07/016(4 weeks)

DEPARTMENT OF MECHANICAL ENGINEERING

GREATER NOIDA INSTITUTE OF TECHNOLOGYAffiliated to Dr. A.P.J. Abdul Kalam Technical University, Lucknow, UP,

(Formerly Uttar Pradesh Technical University, Lucknow, U.P)August-2016

ACKNOWLEDGEMENT

I would since rely like to thank the employees and the officers of TKD, TUGALKABAD 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 (CWI /TTC) and JANARDAN PRASAD(JE/HWS), Mr.

Vipin Srivastava (JE/HWS), Mr. Arvind Kumar(JE/HMS), Er. OM KANT (SSE/HMS) who was

instrumental in arranging the vocational training at TKD, NEW DELHI , an without whose help and

guidance the training could not have materialize.

I express my deep sense of gratitude to Mr. S.P. Singh (Principal, TTC). .

ABSTRACT

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 fara way from theoretical one. We learn in class room

can give the practical exposerreal 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 apart of academic syllabus of four-year degree course in Mechanical Engineering,

every student is required to under go a practical training.

I am student of third 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.

TABLE OF CONTENTS

CHAPTER-1 Introduction to Indian Railway………………………………….

CHAPTER 2 History…………………………………………

CHAPTER 3[3.1]. Conclusion..

………………………………………………….CHAPTER 4[4.1]. Future scope…..………………...…………………………….[4.2].Bibliography….………………………………………………

CHAPTER 1

INTRODUCTIONOFINDIAN RAILWAY

Indian Railways is the state-owned railway company of India. It comes under the

Ministry of Railways. Indian Railways has one of the largest and busiest rail networks in the world,

transporting over 18 million passengers and more than 2 million tones’ of freight daily. Its revenue is

Rs.107.66 billion. It is the world's largest commercial employer, with more than 1.4  million

employees. It operates rail transport on 6,909 stations over a total route length of more than

63,327 kilometers (39,350 miles). The fleet of Indian railway includes over 200,000 (freight)

wagons, 50,000 coaches and 8,000 locomotives. It also owns locomotive and coach production

facilities. It was founded in 1853 under the East India Company.

Indian Railways is administered by the Railway Board. Indian Railways is divided

into 16 zones. Each zone railway is made up of a certain number of divisions. There are a total of

sixty-seven divisions. It also operates the Kolkata metro. There are six manufacturing plants of the

Indian Railways. The total length of track used by Indian Railways is about 108,805 km (67,608 mi)

while the total route length of the network is 63,465 km (39,435 mi). About 40% of the total track

kilometer is electrified & almost all electrified sections use 25,000 V AC. Indian railways uses four

rail track gauges

Indian Railways operates about 9,000 passenger trains and transports 18 million

passengers daily. Indian Railways makes 70% of its revenues and most of its profits from the freight

sector, and uses these profits to cross-subsidies the loss-making passenger sector. The Rajdhani

Express and Shatabdi Express are the fastest trains of India.

GT

46PAC)locomotivesandfamilyof 710engineshasbeensignedwithelectro motive division

ofGENERLMOTORSofUSAformanufacture inDLW. The productionoftheselocomotiveshasnow

startedandthusDLW isthe only manufacturers ofDieselElectricLocomotiveswithbothALCO and

GeneralMotorstechnologiesinthe world.

BriefHistory :

Setupin1961asagreen-fieldprojectintechnicalcollaborationwith

ALCO/USAtoManufactureDieselElectric Locomotives.

Firstlocomotive rolledoutanddedicatedtonationinJanuary,1964.

Transfer-of-TechnologyagreementsignedwithGeneralMotors/USAin October,95

tomanufacture state-of-the-art hightractionAC-ACdiesel locomotives.

A flagship companyofIndianRailwaysofferingcompleterangeof

flankingproductsinitsarea ofoperation.

State-of-theartDesignandManufacturingfacilitytomanufacturemore

than150locomotivesperannum withwiderangeofrelatedproductsviz.

componentsandsub-assemblies.

Unbeatable trail-blazing trackrecordinprovidingcost-effective, eco-

friendlyandreliablesolutionsto ever-increasingtransportationneedsfor over

threedecades.

Fullygearedtomeetspecific transportationneedsbyputting Price-Value-

Technologyequationperfectlyright.

A large baseofdelighted customers amongmanycountries viz.Sri Lanka,

Malaysia,Vietnam,Bangladesh,Tanzania tonameafew,bearing testimonyto

productleadershipinitscategory.

SALIENT FEATURE

Annual production capacity` 225 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 Sq.

Covered area of other

Service buildings 73700 Sq.m

Electrical power requirement 3468 KVA

(Average maximum demand)

Electrical energy consumption

(units/year) 19.8 million

Stand by power generation capacity 3000 KW

PRODUCT OFDL W:

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. Theproduct range available is as under:

WDG4

WDP4

4000HP AC/ACFreightTraffic Locomotive

4000HPAC/AC BroadGauge HighSpeed

Locomotive

WDG3D 3400HP AC/AC BroadGauge MixedTraffic

Micro-Processor ControlledLocomotive.

WDM3C Locomotive.3300HP AC/DCBroadGauge MixedTraffic

WDM3A

Locomotive.3100HP AC/DC BroadGauge MixedTraffic

WDP3A 3100HP AC/DC BroadGauge HighSpeed

Passenger Locomotive.

WDG3A 3100HP AC/DC BroadGauge FreightLocomotive.

WDM2

Locomotive.

2600HP AC/DC BroadGauge MixedTraffic

WDP1

Locomotive.

2300HP AC/DC BroadGauge IntercityExpress

WDM7

Locomotive.

2150HP DC/DC BroadGauge MixedTraffic

WDM6

Locomotive.

1350HP DC/DC BroadGauge MixedTraffic

YDM4 1350HP AC/DC & DC/DC BroadGaugeMixed

traffic Locomotive.

EXPORTLOCO 2300HP AC/DC Meter Gauge/Cape gaugeMixed

Traffic Locomotive.

DieselGeneratingSets 800KWto2500KW

SparePartsforengines, locomotivesandgeneratingsets.

DESI GNO FFIC E:

Prepare diag.of each partandsenttoMaterialControl& informtimelyinany change inanypartstorelative department.

3D MODELOFDIESEL LOCO MOTIVE

M AT E RIAL CO NTROLOFFIC E : Preparedmateriallist(ml) whichconsistsdiag.&qty.of each partandsentto

storedepartmentsfor purchase.

FORKLIFT TRUCK

STOREDEP AR T M EN T :After receivingof ML,Store Departmentsscrutinythe ML, take

Funds&vettingfromAccountdepartment&thenissuetenders, OpenTenders& Purchase Order issued. After Receivingof Materialinspectionhasdone by InspectionDepartment.

INSPEC T I O N D EPART M EN T : After Receivingof MaterialinspectionhasdonebyInspectionDep’t.If material

isOK,thenReceiptNoteissuedbyStore Dep’tandsenttoAcct.Departmentfor paymenttofirm.IfmaterialisnotOK,theninformingtofirmtocollectthe

rejectedmaterial.

AC C O UNTDE P ART M EN T :Checkallthepurchase,givenconcurrencefor purchase,vettthe

ML/Requisition&paymenttofirms.

PLANNI N GOF F IC E : Prepare JPO,MonthlyProductionProgram,Scheduling,Processing,Rate Fixing,Issue

WorkOrders,Schedule Orders,IssueJobcard&otherproduction Documents.PreparingDLWBudget&SenttoRlyBoard.

PROGR E SS O FF IC E :After openingof workorderscollecttheprod.DocumentsfromPCOandhand over tousershop

drawthe materialfromdepot&giventoshop& handover the readymaterialofshoptousershop/store.After completionofwork,closethe workorder.

PRODUCT I ONS HO PS :

Productionshopsaredividedinthreedivisions-1. BlockDivisions

2. Engine Divisions3.LocoDivisions

B L O C KDIVIS I O N : 1.HeavyWeldShop

2.HeavyMachine Shop

ENGINEDIV I S I O N : 1.Engine ErectionShop2.Engine TestingShop3.LightMachine Shop4.SubAssemblyShop

5.Rotor Shop6.HeatTreatmentShop

LO C ODIV I SI ON : 1.LocoFrame Shop

2.Pipe Shop3.TruckMachine Shop

4.TractionAssemblyShop5.SheetMetalShop

6.LocoAssemblyShop7.LocoPaintShop8.LocoTestShop

SERV I CE S H O PS : 1.Maintenance Areas#1,2,32.ToolRoom3.CentralTransportShop

PER S O NNAL D EPART M EN T : Prepare paymentof Staff, Leave Record,PersonalRecordof everyemployee, Housingallotment, welfare ofstaff etc.

H EA L T HD E P A RT M EN T : Havingfacilityof Indoor&Outdoorpatients.

CIV I LDE P AR T M EN T : Maintenanceof colonyquarters, upgradationof facilitiesinquarters,sanitation etc.

E L EC T RICAL D EPART M EN T : Maintenanceof Lightinginquartersandinworkshop,electricalworksin locomotive etc.

T E C H NI C AL T RANI N GC E N T E R : Provide trainingtoallemployeesattime totime torefreshupdate their knowledge.

RESE ARC H& D E V EL O P ME N T :

1. R &D–a Customer CentricActivityCommittedtoInnovationand

ContinuousImprovement;

2. HighlyskilledManpower capableof handlingcomplete R&Dactivities;

3. Asophisticateddesign centerwith modern CAD/ CAE workstations equippedwithUnigraphicsandAnsys;

4. Back-upsupport from RDSO, a centralized R&D organization at corporate level;5. Severalmilestonesinthepast- anenviablepedigreeviz.

a. originalALCOdesignmade 7%more fuelefficient;

b.many design improvements leading to better performance, incorporatedinthe originalALCOdesign;

c. manynewdesignsforlocomotivessuchasWDP1,WDG2,WDP2 toname a few;

RECE NTM IL ES TONES&F UTU REPLA N :

M I L ES T O NES A C H I E VE D: Transferoftechnology (TOT) -- An addedfeatherinthe cap: -

Agreement w i t h G e n e r a l M o t o r s o f U S A f o r t e c h n o l o g y t r a n s f e r t o manufacture high

horse-powerGT46MAC4000HPAC/AClocomotive in India; OnlycountryoutsideNorth-Americatohavethisbleedingedgetechnology Many

export/repeatorderscompliedsuccessfully inrecentpast andmany moreinthe pipeline;Suppliedmorethan400locomotives to variousnon- railway

customers;Emergingasaleadingmanufacturer ofALCO/GM locomotivesfordevelopingcountries.

FUTUREPLA NS :

• AssimilationofGMtechnologytomanufacturetheirlatest710seriesof dieselelectriclocomotives;

• Toemerge as a globallycompetitive locomotive manufacturer;

• Todevelopasan exporthubfor ALCO/GM locosfor Asianmarket;

• To follow an export led growth strategy through continuous improvement;Costeffectivenessandtechnology/productup-gradationasa keytoretain globalcompetitivenessbyputtingprice-value-technologyequationright.

W D P 4 , 400 0HP P AS S E N G ERL O C O MO T I V E

GeneralCharacteristic

InstalledPower

AxleLoad

Gauge

Wheelarrangement

Wheeldiameter

Height

Width

OverallLength(OverBufferBeam)

Weight

Maxtractiveeffort

Maximumspeed

Fueltankcapacity

LocomotiveControl

4000HP

19.5T

1676mm

A-A-II-A-A

1092mm

4201mm

3127mm

19964mm

117T

27T

160Mph

4000lots

EM2000withSIBAS-16TractionControl

WDP4-4000HPGOODSLOCOMOTIVE

TRACTIVEEFFORT& POWERCHART

INT RODU CT IO NOFHEAV YWELD INGSH OP:

In theDLW there arebasically three typeofweldingusedinHWS. The weldingquality ofDLWisvery highquality.Afterthemachiningprocesswe can’tsaythatthispiece isno

singlepiece.1. Submergedarc welding

2. Manualmetalarc welding3. MIGwelding

SUBM ERGEDA RCWELDI NG :

In submergedarc weldingthewelding processwill becoveredwith the fluxso thatitwillnotreactwithoxygenandnitrogen.Because ofthe versatility ofthe processandthesimplicity ofitsequipmentandoperation,shieldedmetalarc

weldingisoneoftheworld'smostpopularweldingprocesses.Itdominatesotherweldingprocessesinthemaintenanceandrepairindustry, andthoughflux-

coredarcweldingisgrowinginpopularity,SMAWcontinues tobeusedextensively intheconstructionofsteelstructuresandinindustrial fabrication.Theprocessisusedprimarilytoweld iron

andsteels(includingstainlesssteel)butaluminum,nickeland copper alloysalso beweldedwith thismethod.

GM AWC OM P O NENT S:

1. DC or DirectCurrentpowersupply2. Electrodeor wire feedcontroller

3. Wire drive roller assembly4. Shieldinggassource(cylinder) & regulator

5. Manuallyheld Gun& groundclamps6. Wire reel

M IGWEL DI NG :

MIGweldingcan be usedformosttypesofmetals; steel,stainless steel,aswell asaluminum.Butweldingaluminumisverydifferentfrom weldingmildsteel

becausealuminumisametalthatisdifferentfrom steel.So whenweweld aluminum,wehavetouseotherparameters,othersettings.Aluminumhasa

lowermeltingtemperaturethanmildsteel,forexample,soyoushouldexpect thatweshouldusealowerheatinputbutinspiteofthis.So wehavetousea higherlocal heat-input

butafasterwelding speedthanwith steeltoget good fusionandpenetration.Thissoundsasifaluminiumweldingis difficult,butit's

not.Theweldingsetsthatweuseadjusttheweldingparametersautomatically, so theweldercanconcentrate ontheweldingoperation,the movementof the weldinggunandthe

weldpool.

Dip(shortarc)transfer Arcvoltage:15 - 22V

Current:>175AWirestickout:5 - 12mm

Metals:steelandsteel alloysConnection:dc electrode

positiveContacttube:5mminfront

ofnozzletip

SpraytransferArcvoltage:27 - 54V

Current:<200AWirestickout:15-20 mm

Metals:aluminium(other metalsinflatposition)

Connection:dc electrodepositive

Contacttube:5mm insidenozzletip

INTRODUCTI ONTOLIGHTMACHINESHOP

Thisshopdealswiththe matchingofvarioussmallcomponentsrequired for thepower packunitsuchas, camshaft,connectingrod, liners, gears,levers,F.P.Support,Pistonpin,

nutsandboltsbushes,various shaftsetc.

The lightmachineshopdividedintothe followingsection: -

1.Econometric Section2.Grindingsection

3.Gear section4.Camshaftsection5.A.T.L. section

6.Belchingsection7.Connectingrodsection

8.Lathe section9.Linerssection

10.Drillingsection11.Millingsection

01.Ec o n o m etr i c s ec t io n : Thissectionmanufacturingvarioussizesetc. M a ch i ne p r o v i ded: -econometric machine,do-allmachine,beltgrinding machine (for

controlshaftfeed)

02.Ge ar - S ec t io n: Thissectiondealstomakingvariousgearsimpeller suchas:camshaftgear, crankshaftgear, extensionshaftgear,impeller gear (follower &drive)and broachingMachineProvided: -

(a) gearhobblingmachine

(b) gearshavingmachine

(c) V.T.L.machine(d) Radialdrillingmachine

(e) Broachingmachine(f) Centre millM/C

03.G rindingSec t i o n: Inthissectionthe varioussmallcomponentsare grindingasper required finishingafter

machiningoperationandeachcomponentshavinggrinding allowance (G.A.)mainpistonpin,impellerandfuller andfollower gear,

pinvalveguide,variousstuds.Camroller, seat(V/C Q‘X’ head) spider variousbushesetc.

Ma chinepro v id ed : a. cylindricalgrindingmachine

b. internalgrindingmachinec. Centre lessgrindingmachine

d. threadrollingmachinee. universalgrindingmachinef. externalgrindingmachine

04.C a m sh a ftsectio n : Thissectionmakingcamshaft(bothB.G.& M.G.) withcompleted

machiningoperationbyvariousspecialtype of machine.InB.G.08no’sper locoandinM.G.03perloco.

Ma chine P r ov id ed : 1. Centre millmachine2. Autolathe machine3. Gundrillmachine

4. Externalgrindingmachine5. Lathe machine

6. Camgrinding machine7. Radialdrillingmachine

8. Camangle checkingmachine9. Magna fluxmachine

05.Aut o m a t i cTurr e tL a the ( A .T.L) S ectio n : Thissectionmanufacturingvarioustypesof smallcomponentsfor Power packengine

suchas:

Lockspringseat(V/L&X-Hd) spewingseat.Ballend,cupendad. Screw (X-HD& V/L) copscrewsL.A.S.retainer, springlever,F.P.inlet, PorgBkt. pistonpinliner sleeve,

bodyouter ringspicier etc.

Ma chine P r ov id ed : 1. M.T.L.(Bartype,chucktype)

2. U.T.L.TheA.T.L.sectionisthevitalsectionofthisshop.Maximumsmall componentsare

manufacturinginthe section.

06.BenchingSe ct i o n: In this section the benchingoperation of theentirecomponentwhichare manufacturing

intheshoparedone here.Inthebenchingsection, there hawinghandcuttermachiningandbeltgrindingmachine,with the half of these machine

bar removingfromallthe components.

07.C o nnectingr o dsection: Inthissectiontheconnectingrodismade.Allthemachiningoperations ofthe connectingrod,completedherewiththe help of varioustypesof machine. Theconnectingrodhastwoparts, oneiscapandother isrod. Thematerial of

theconnectingrod issteepforging. InB.G.16 perloco andinM.G.6per loco.

Ma ind i m ensi o n s : 1. crankbore (bigbore)=6-411”to6.421”2. pistonpinbore (smallbore) =3.998” to3.999”

3. Distance BetweenTwo= 20.995” to21.000” bareCentre4. RodThickness=3.020” to3.022”

5. Weight= 32Kg950gramto32Kggram.6. Pressure Torque =150P.S.I.

08.L a thesectio n :This section deals various types tropical small components are

manufacturing.Centre lath machinesoarprovidedinthissection.Thecomponentsare:brasssleeve,wearplate,valveguide,longstud,

shaftetc.IndrumtypeturretlatheM/Cmanufacturingpincamroller,cupend, bushwasher etc.

09. C y linderLinerSec t i o n : Inthissection. cyclelinermachineoperationhasdoneherebythe

varioustypeofm/cs.thematerialofthecylinderLinerisspecialCast ironandthe settheper locoisinB.G. 16andinM.G.6cylinder.

Ma inD i m ensi o n : - 1. Length2115/16+1/64

2. Insidedia.roughhoning-9.010”3. Insidedia.finishhoning– 9.015”

4. outsidedia. –10.00”5. Dia.ofgroove –10.749to10.750”

Ma chinepr ov id e d : - 1. Shotblastmachine.2. Verticalboringmachine

3. Autolathe machine.4. Honingmachine.

5. Cylindricalgrindingmachine.

10.DrillingSe c ti o n :Inthissection dialswithvariousTypesof drilling,reaming,counter bore spot

tracingandcountersinkingoperationdone of various small components.Thecomponentsare,F.P.support,P.R.Lighter,Xhead,ValveLever,

SpringLever,Brag,Bracket,Pin,EccLever, Upperhousingetc.

Ma chine P r ov id e d : - 1.RadialdrillingMachine,

2. Gangdrillingmachine of multyspindledrillingmachine3.DrillingMachine4.Electronic drillingmachine.

11.M illingM a chin e : -This sectionmanufacturingvarioustypesofmillingoperationofthe componentsin

differenttypesof millingmachine-

Ma chine P r ov id e d : - 1.Verticalmillingmachine2.Horizontalmillingmachine3.Universalmillingmachine.

INTRODUCTI ONTO MACHIN SHOP

Machineshopworkisgenerally understoodtoincludeallcold-metalworkby whichanoperator,usingeitherpowerdrivenequipmentorhandtools,removes

aportionofthemetalandshapesittosomespecifiedform orsize.Itdoesnot includesheetmetalworkandcoppersmithing.Thefunctionof allmachine tools

istoproducemetalpartsby changingtheshape, size, orfinishofapieceof material.The shapeofa partmadewithamachine toolislimitedbythe typesof motionthe toolcanapply.

Standardmachine toolsare groupedinsixbasic classes:

1. LATHES2. DRILLINGMACHINES

3. SHAPERS4. PLANERS

5. MILLINGMACHINES6. GRINDINGMACHINES

LA T H E : The lathe isusedforturningvariousmetalsagainstacuttingtoolthatshapesit tothe

desiredproduct. The enginelatheisamachine toolthatproducesa cuttingactionbyrotatingtheworkpiece againstthe cuttingedge of thetool.

DRI L L I NGM A C H IN E S : The drillingmachine isamachine toolthatproducesthe necessarycutting

actionbythe rotationof amultiple edgecuttingtool.

S H A PI N GA N DPLANI N GM A C H IN E S : Bothof these machinescanmachine flatsurfaceswitha singlepoint

reciprocating,motionisappliedtoboththeworkpieceandtoolinthese machines.

M I L L I NGMA C H IN E S : A millingmachineprovidescuttingactiontoarotatingtool. Thevertical

millingmachine isusedtocut, shape,andfinishmetalobjects.

G RI N DINGM A C H IN E S Agrinder differsfromother machinesinthatitusesatoolmade of emery,

Carborundum,or similar materials. The wheel,made upof manytinycutting points,cutswiththe entiresurface area thatcomesincontactwiththe material beingground.

Grinderscutwithagrindingaction,removingmaterialinthe formof tinyparticles.

SAFETYRULE SF ORMA CHINETO OLS :

The followingaregeneralsafetyrules foranymachinetool:

1. Gears,pulleys,belts,couplings,endsofshaftshavingkeyways,andother revolvingorreciprocatingpartsshouldbe guardedtoaheight of6feet above

thefloor.Theguardsshouldberemovedonly forrepairingor adjustingthe machine andmustbe replacedbefore operatingit.

2. Safety se tscrewsshouldbeusedincol lar sandon al l r evo lv ingorreciprocatingmembersofthe machinetoolor itsequipment.

3. Donotoperate anymachine toolwithoutproper lighting.4. Neverattempttooperateanymachinetooluntilyoufullyunderstandhow

itworksandknowhowtostopitquickly.5. Neverwearlooseortornclothingandsecurelonghair,sincetheseitems

canbecomecaughtinrevolvingmachineparts.Tiesshouldberemoved andshirtsleevesshouldberolledupabovetheelbow.

6. Glovesshouldneverbewornwhenoperatingmachineryexceptwhen absolutelynecessary.7. Alwaysstopthemachine before cleaningitortakingmeasurements of the workpiece.

8. Donot lubricate amachinewhile itisinmotion.Injuryto the operatorand damage tothe machine mayresultfromthispractice.

9. Alwayswearsafetyglassesorgoggleswhileoperatingmachinetools.Also,wearrespiratory protectionifoperationcreateshazardousdust.All personsin

theareawhere power toolsare beingoperatedshouldalsowear safetyeye protectionandrespiratorsasneeded.

10.Knowwheretireextinguishersarelocatedintheshopareaandhow touse them.11.Never wearjeweler while working around machine tools. Rings,

watches,orbraceletsmaybecaughtinarevolvingpartwhichcouldresultinthe handbeingpulledintothe machine.12.Avoidhorseplay.Toolsareverysharpandmachinesaremadeofhard steel.

Anaccidentalslipor fallmaycause a seriousinjury.13.Neverusecompressedairwithoutasafety nozzletocleanmachinesor

clothing.Itwillblowsharp;dangerousmetalchipsalongdistance.14.Never place tools or othermaterials onthemachine table.Cluttering upa machinewithtoolsormaterialscreates unsafeworkingconditions.Usea benchor

tablenearthemachine for thispurpose.15.Alwaysuse aragwhen handlingsharpcutterssuchasmillingcuttersand endmills.

SUB ASSEMBLY SHOP

This shop deals with following section: --1.Turbo machining section

2.Cylinder head & shot blast section

3.Fuel pump, Support, Cam shaft ate section

4.Cylinder head

5.Turbo

6.Governor, Water Pump, Fan drive, Lube oil Pump, After cooler assembly section.

CYLINDER HEAD SECTIONThe lay out of this section is product type. There are different

machines had do set up per sequence of operation of cylinder head. A milling machine provides profile cutting and taper profile

according of the template. The tracer runs and cutter forms shaper radial drilling machine. This machine provides for drilling tapping. Core boring operation as per

drawing

HEARALD BOROING MACHINE This machine having four spindles for boring of guide hole, air &

exhaust it dimensions are— 1.Valve inner sheet die 4 hole- 3.1805-3.18152.Guide hole die- 1.0625‖-1.0635‖3.Valve sheet depth (E1, E2, A1)- 0.740‖ to 0.745‖ & A2- 0.950‖4.Depth of sheet (A1 E1, E2)- 0.205‖-0.215‖5.Spring sheet depth (E1, E2, E1)- 1.865‖-1.885

CONTROL SHAFT ASSEMBLYIt is a link between Governor & Fuel injector pumps by which the

mechanical power from the governor transmitted to the fuel injection pump Racks. It means to control the amount of fuel according to the requirement of load

& speed. EXPLOSION DOOR COVER ASSEMBLY. It is special type of main base door cover which when the crank

case exhauster failed to workCAM SHAFT VIBRATION DAMPER ASSEMBLY

When vibration developed on the cam shaft will be damped by this assembly.

O.S.T. HOUSING ASSEMBLY

This assembly controls the R.P.M. of crank shaft and keeps it a specified limit (1000 to 11500 p.m.). When OST is operated in the case 16-

cylinder engine the engine RPM will come in ideal but in case of 16 cylinder engines will be stopped.

FUEL PUMP SUPPORT ASSEMBLYIt is a support of the fuel pump on which the fuel injection pump is

mounted and the power of cam shaft is transmitted to operate fuel injection pump through the cross head lighter & to operate push rod by PRD. Lifter by which the

inlet & exhaust valve open & closed through the valve lever & yokes.

ACCELERATION CONTROL DEVICEBy this device by monopoly of the driver is controlled the air & fuel

supply is controlled by according to the fuel ratio. It is controlled the proper fuel and air ratio.

FIG NO 4(Schematic diagram of ALCO Engine)

ROTOR SHOP

This shop is deals with the manufacturing of Turbocharger. Turbocharger is known as the Heart of Diesel Locomotive. Basically in this

section manufacturing of assembly & sub assembly of Turbocharger is made. But the outer casing of Turbocharger is made up in Heavy Machine Shop.

Turbocharger is use for the providing fresh air to the engine. Due to this the efficiency & power generated by engine is increased. For the running of

Turbocharger, we are not using any extra energy source like generator, motor etc. For starting of Turbocharger generally we use exhaust gasses.

COMPONENTS OF TURBOCHARGER

For assembly of Turbojet following parts are manufactures in rotor shop

1. Impeller 7. Thrust Washer

2. Inducer 8. Key3. Nose piece 9. Oil Slinger

4. Stud Rotor 10. Turbine Disc

5. Nut 11. Turbo Shaft

6. Washer 12. Lock plate

ASSEMBLY OF TURBOCHARGER

The assembly of turbocharger is done by dividing whole turbocharger in three parts. These are as follows

1. Rotor

2. Compressor

3. Casing

1. ROTOR

Rotor is the inlet part of turbocharger which is comprises with following parts. Turbo Disc, Rotor stud, Turbo shaft, thrust collar, Nose disc,

Washer & Nut. Rotor is rotating at speed of 18000 rpm & working at high

temperature due to that the rotor is made of steel.

2. COMPRESSOR

Compressor is the combination of impeller & inducer. Impeller is made up of Al-alloy. Impeller & inducer is use for sucking of fresh air from environment

. FIG NO (5) TURBOSUPER CHRAGER

3. CASING

Casing is made of M.S. & also a special type of coating is done. Due to that coating it can easily resist the heat.

For the proper working & life of Turbocharger balancing of impeller, inducer & turbine disc is done by help of Dynamics Balancing Machine.

For the proper working & life of Turbocharger balancing of impeller, inducer & turbine disc is done by help of Dynamics Balancing Machine.

1.

2. TURBO SUPERCHARGER AND ITS WORKING

3. PRINCIPLE

The exhaust gas discharge from all the cylinders accumulate in the common exhaust manifold at the end of which, turbo- supercharger is fitted. The gas under pressure there after enters the turbo- supercharger through the torpedo shaped bell mouth connector and then

passes through the fixed nozzle ring. Then it is directed on the turbine blades at increased pressure and at the most suitable angle to achieve rotary motion of the turbine at maximum

efficiency. After rotating the turbine, the exhaust gas goes out to the atmosphere through the exhaust chimney.

The turbine has a centrifugal blower mounted at the other end of the same shaft and the rotation of the turbine drives the blower at the same speed. The blower connected to the

atmosphere through a set of oil bath filters, sucks air from atmosphere, and delivers at higher velocity. The air then passes through the diffuser inside the turbo- supercharger, where the

velocity is diffused to increase the pressure of air before it is delivered from the turbo- supercharger

Pressurizing air increases its density, but due to compression heat develops. It causes expansion and reduces the density. This effects supply of high-density air to the engine.

To take care of this, air is passed through a heat exchanger known as after cooler. The after cooler is a radiator, where cooling water of lower temperature is circulated through the tubes and around the tubes air passes. The heat in the air is thus transferred to the cooling water and

air regains its lost density. From the after cooler air goes to a common inlet manifold connected to each cylinder head. In the suction stroke as soon as the inlet valve opens the booster air of

higher pressure density rushes into the cylinder completing the process of super charging. The engine initially starts as naturally aspirated engine. With the increased

quantity of fuel injection increases the exhaust gas pressure on the turbine. Thus the self-adjusting system maintains a proper air and fuel ratio under all speed and load conditions of the

engine on its own. The maximum rotational speed of the turbine is 18000/22000 rpm for the Turbo supercharger and creates max. Of 1.8 kg/cm2 air pressure in air manifold of diesel engine,

known as Booster Air Pressure (BAP). Low booster pressure causes black smoke due to incomplete combustion of fuel. High exhaust gas temperature due to after burning of fuel may

result in considerable damage to the turbo supercharger and other component in the engine.

FIG NO (6) TURBOSUPERCHRGER WORKING

EXPRESSOR

FIG NO (7) EXPRESSOR

In Indian Railways, the trains normally work on vacuum brakes and the diesel locos on air brakes. As such provision has been made on every diesel loco for both vacuum and

compressed air for operation of the system as a combination brake system for simultaneous application on locomotive and train.

In ALCO locos the exhauster and the compressor are combined into one unit and it is known as EXPRESSOR. It creates 23" of vacuum in the train pipe and 140 PSI air pressure in the

reservoir for operating the brake system and use in the control system etc.

The expressor is located at the free end of the engine block and driven through the extension shaft attached to the engine crank shaft. The two are coupled together by fast coupling

(Kopper's coupling). Naturally the expressor crank shaft has eight speeds like the engine crank shaft. There are two types of expressor are, 6CD,4UC & 6CD,3UC. In 6CD,4UC expressor

there are six cylinder and four exhausters whereas 6CD,3UC contain six cylinder and three exhausters.

WORKING OF EXHAUSTER

Air from vacuum train pipe is drawn into the exhauster cylinders through the open inlet valves in the cylinder heads during its suction stroke. Each of the exhauster

cylinders has one or two inlet valves and two discharge valves in the cylinder head. A study of the inlet and discharge valves as given in a separate diagram would indicate that individual

components like

(1) plate valve outer

(2) plate valve inner

(3) spring outer

(4) spring inner etc. are all interchangeable parts.

Only basic difference is that they are arranged in the reverse manner in the valve assemblies which may also have different size and shape. The retainer stud in both the

assemblies must project upward to avoid hitting the piston.

The pressure differential between the available pressure in the vacuum train pipe and inside the exhauster cylinder opens the inlet valve and air is drawn into the cylinder from train

pipe during suction stroke. In the next stroke of the piston the air is compressed and forced out through the discharge valve while the inlet valve remains closed. The differential air

pressure also automatically opens or close the discharge valves, the same way as the inlet valves operate. This process of suction of air from the train pipe continues to create required amount of vacuum and discharge the same air to atmosphere. The VA-1 control valve helps in

maintaining the vacuum to requisite level despite continued working of the exhauster.

COMPRESSOR

The compressor is a two stage compressor with one low pressure cylinder and one high pressure cylinder. During thefirst stage of compression it is done in the low

pressurecylinder where suction is through a wire mesh filter. After compression in the LP cylinder air is delivered into the discharge manifold at a pressure of 30 / 35 PSI.

Workings of the inlet and exhaust valves are similar to that of exhauster which automatically open or close under differential air pressure. For inter-cooling air is then passed

through a radiator known as inter-cooler. This is an air to air cooler where compressed air passes through the element tubes and cool atmospheric air is blown on the outside fins by a

fan fitted on the expressor crank shaft.

A safety valve known as inter cooler safety valve set at 60 PSI is provided after the inter cooler as a protection against high pressure developing in the after cooler due to

defect of valves.

After the first stage of compression and after-cooling the air is again compressed in a cylinder of smaller diameter to increase the pressure to 135-140 PSI in the same way. This is

the second stage of compression in the HP cylinder. Air again needs cooling before it is finally

sent to the air reservoir and this is done while the air passes through a set of coiled tubes after cooler.

CONCLU SION

REC E NTM I LE S T O NES&F U T U RE P L A N :

M IL EST ONESA CHIE VED :

Tr a nsferofT e c h n o l og y(T O T ): Anaddedfeatherinthe cap:-

1.AgreementwithGeneralMotorsof USAfor technologytransferto manufacture highhorse-power GT46MAC4000HP AC/AC locomotive in India;

2.OnlycountryoutsideNorth-America tohave thisbleedingedge technology;3.Manyexport/repeatorderscompliedsuccessfullyinrecentpastand many more inthe

pipeline;4.suppliedmore than400 locomotivestovariousnon-railwaycustomers;

5.Emergingasa leadingmanufacturer ofALCO/GM locomotivesfor developingcountries.

FUTUREPLA NS :

1.GM technologytomanufacture their latest710seriesofdieselelectric locomotives;2.Toemerge as a globallycompetitive locomotive manufacturer;3.TodevelopasanexporthubforALCO/GM locosfor Asianmarket;

4.Tofollowanexportledgrowthstrategythroughcontinuousimprovement5.Costeffectivenessandtechnology/productup-gradationasakeytoretain globalcompetitivenessbyputtingprice-value-technologyequationright.

BIBL IOGR APHY

1. www.in di anrail ways .gov.in

2. Cris-dlw.cirs.org.in

3. www.irfca.org