SEMINAR ON INDUSTRIAL TRAINING AT D.M.W. PATIALA

GURU NANAK INSTITUTE OF TECHNOLOGY

By lakhvinder singh 6312507

INTRODUCTIONRailways serve the people of India since 1853.

Indian Railways are the biggest organization in our country, which is engaged in transportation.

First train moved on: April 16, 1853First train run between: Bombay to ThaneFirst locomotive named: Lord Falkland

D.M.W. ,PATIALA

Diesel Loco Modernization Works.

Earlier Name- Diesel Cargo Works(D.C.W.)

First Stone was laid on 24th October,1981 by the minister of Railways Shri Kedarnath Pandey.

OBJECTIVESModernization of LOCO.Remanufacture of ALCO LOCO.Manufacture of Engine components.Upgradation of LOCO.

LocomotiveA locomotive or engine is a railway vehicle that provides the motive power

for a train. The word originates from the Latin loco – "from a place", ablative of locus, "place" + Medieval Latin motivus, "causing motion", and is a shortened form of the term locomotive engine.

The first successful locomotives were built by Cornish inventor Richard Trevithick in 1804.

WORKSHOP LAYOUT

Various Shops in DMW Are: -

P.M.S Plant Maintenance Shop

T.R Tool Room

L.M.S Light Machine Shop

C.B.S Carbon Brush Shop

H.T.S Heat Treatment Shop

V.M.S Vehicle Maintenance Shop

T.M.S Traction Machine Shop

M.R.S Main Receiving Shop

H.M.S Heavy Machine Shop

C.L.S Cylinder Linear Shop

P.P.S Power Pack Shop

B.S Bogie Shop

S.S.S Super Structure Shop

L.R.S Locomotive Rebuilding Shop

NOMENCLATURE OF LOCOMOTIVEThe code is of the form [gauge][power][load][series][suffix] GUAGE- W(BROAD) Y (METRE)

Z (NARROW,2.6’) N (NARROW,2’) POWER- D = Diesel C = DC traction A = AC traction CA = Dual-power AC/DC B = Battery electric (rare)

LOAD- M = Multipurpose P = Passenger

G = Goods S = Shunting L = Light Duty (Light Passenger) R = Railcar

SERIES- 1 –over 1000 hp less than 2000hp 2-over 2000 less than 3000 3--over 3000hp less than 4000hp 4-over 4000 less than 5000

SUFFIX-A-100HP B-200HP C-300HP D-400HP

WDM3A MEANS “Broad gauge diesel powered multipurpose 3100hp loco”

Heat Treatment Shop

Requisite heat treatment that is induction hardening, case carburizing etc. is

carried out in the Heat Treatment Shop to develop optimum properties in

the finished components.

Heavy Machine Shop

Engine Blocks of diesel locomotives and Traction Motor Magnet Frames

are machined in this shop.  Precision machining of the Blocks is carried out

on CNC Horizontal Boring & Milling Machine of PAMA, Italy make CNC

machine.

Engine block

Traction Machine Shop

A wide variety of Traction Motors, Traction Generators and Alternators are

rewound / remanufactured in this shop.  Facilities include 500 T Hydraulic

Press for shafting/deshafting, Glass Bead Blasting Machine, Vacuum

Impregnation Plant, HYT Lathe, Dynamic Balancing Machine, etc.

The main functions of this shop are-

Dismantling, Reconditioning and assembly of power pack.

Load testing, specific fuel consumption testing and other types.

WDG2 LOCO WDP2 LOCO

WDG4 LOCO WDP4 LOCO

BOGIE SHOPThis shop is concerned with the manufacturing, remanufacturing and testing of bogie. Bogie is the lower part of the loco, which supports the engine. It is a unit where the main power of the Locomotive is utilized.

Parts of a Diesel-Electric Locomotive

Another view

Diesel EngineThis is the main power source for the locomotive. A diesel engine (also known as a compression-ignition engine) is an internal

combustion engine that uses the heat of compression to initiate ignition to burn the fuel that has been injected into the combustion chamber.

It comprises a large cylinder block, with the cylinders arranged in a straight line or in a V.

Engine view

ENGINE DATA CYCLE: 4 STROKE CYCLE MODEL: ALCO, V –SHAPED, 16 CYL BORE: 9 INCHES (228 mm) STROKE: 10.5 inches (267 mm) Compression Ratio : 12.5 : 1 HORSEPOWER (GROSS): 3300 BHP ENGINE SPEED: 1000 RPM (FULL LOAD)

400 RPM (IDLE) PISTON SPEED (MEAN): 9.89 m/sec Air Fuel Ratio: 13:1. WEIGHT (DRY ENGINE): 19026 kg

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.  .

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. 

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 each of the motors through flexible ducting. 

The blower output also cools the alternators.

Traction MotorSince the diesel-electric locomotive

uses electric transmission, traction motors are provided on the axles to give the final drive. 

These motors were traditionally DC but the development of modern power and control electronics has led to the introduction of 3-phase AC motors.

Pinion/Gear• The traction motor drives the axle

through a reduction gear of a range between 3 to 1 (freight) and 4 to 1 (passenger).

Fuel TankA diesel locomotive has to carry its own fuel around with

it. The fuel tank is normally under the loco frame and This

huge tank in the underbelly of the locomotive holds 2,200 gallons (8,328 L) of diesel fuel.

Sand Box• Locomotives always carry sand to assist adhesion in bad

rail conditions.  • Sand is not often provided on multiple unit trains because

the adhesion requirements are lower and there are normally more driven axles.

Air ReservoirsAir reservoirs containing compressed air

at high pressure are required for the train braking and some other systems on the locomotive. 

These are often mounted next to the fuel tank under the floor of the locomotive.

Air Compressor• The air compressor is required

to provide a constant supply of compressed air for the locomotive and train brakes.

Radiator and Radiator Fan

The radiator works the same way as in an automobile.  Water is distributed around the engine block to keep the temperature within the

most efficient range for the engine.  The water is cooled by passing it through a radiator blown by a fan driven by

the diesel engine.

Turbo ChargingThe amount of power obtained from a

cylinder in a diesel engine depends on how much fuel can be burnt in it. 

The amount of fuel which can be burnt depends on the amount of air available in the cylinder.  So, if you can get more air into the cylinder, more fuel will be burnt and you will get more power out of your ignition. 

Turbo charging is used to increase the amount of air pushed into each cylinder. 

Turbocharging gives a 50% increase in engine power.

Locomotive DataGeneral Data Of Locomotive:-Model No. : WDM2Specification : 16 cylinder V-type 4 stroke Diesel EngineType : Co-CoPower : 700hp, 1400hp, 2400hpMaximum Speed : 120 kphGear Ratio : 68/18Compression Ratio : 16:1Cylinder Bore : 230mmCylinder Stroke : 279mm

Maximum Overall Dimension :-Height : 4185mmWidth : 3010mmLength : 17120mm

Capacity:-Fuel : 5000 ltCooling Water : 1210 ltLube Oil : 910 ltWater Expansion : 155 ltSand : 0.4 m3

Wheel Base:-Wheel Dia : 1092mmWheel Base : 12834mmTraction Motor : Bhel 165Track Gauge : 1676mmBrake Equipment : Vaccun/Air

Auxiliary Horse Power Requirement:-

Auxiliary Generator Maximum : 17HPExciter Maximum : 12HPTraction Motor : 400HPBlower at full speed : 62HPRadiator Fan : 80HPExpresser Unloaded at 1000 rpm : 13 HP

BOGI ASSEMBLY SHOP

bogie assembly shop

A bogie is a wheeled wagon or trolley. In mechanics terms, a bogie is a chassis or framework carrying wheels, attached to a vehicle.

Usually the train floor is at a level above the bogies, but the floor of the car may be lower between bogies.

Parts Of Bogi

Axle, Wheel & Axle Box assembly

These wheels are having wear adapted profile to RDSO drawing.

Journal bearings & adaptor The bogie frame is supported on axles through “soft primary”

suspension consisting of twelve single helical coil springs, two springs mounted on each bearing adapter (axle box), to provide ride quality and equalization of wheel-set loads.

Bearing adapter are fitted with tapered roller pre-lubricated, pre adjusted & sealed bearings.

Bearing adapter

single helical coil springs

Sealed bearings

TPU shims

ASSEMBLY PROCESS:PRESS BULL GEAR ON AXLE.

SHIFT ABOVE ASSEMBLY AT BEARING HOUSING FITTING STAND.

FIT THE BEARING HOUSING AND BOLTING .

ASSEMBLE SEAL , CAP AND TAPER ROLLER BEARING

BOLTING .

NOW, SHIFT THIS ASSEMBLY ON WHEEL & AXLE PRESS MACHINE.

Bogie Shop

The locomotive bogies are rebuilt with new wheel sets, suspension

bearings and remanufactured traction motors. Separate shop has been set up

for machining of wheel sets and assembly of locomotive bogies.

SAW Features•High Productivity, high amperages may be used•Easy to de-slag •High Quality•Deep penetration•Excellent mechanical properties•Environment friendly•Very little fume•No radiation•Easy operation

LOCO & ENGINE TEST SHOP

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.

Load testing For 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.

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.Intermediate runs 12 runs of 30 min duration each

from 400 to 1000 rpm.

Diesel electric locomotive In a diesel-electric locomotive, the diesel engine drives an electrical generator or

alternator whose output provides power to the traction motors. There is no mechanical connection between the engine and the wheels.

Development in Diesel LocomotiveIncrease in power per Cylinder.

Increase in overall efficiency.

Fuel Efficient & Lube efficient Engine.

High Adhesion Loco.

160 Kmph Speed Of WDP2 Loco.

Parts in power pack shop

Some components

Stripping section in LRD shop