Ramanand Sharma completed a 4-week internship at Banaras Locomotive Works in Varanasi, India. He observed operations in the Loco Assembly Shop, where electric locomotives have their propulsion systems and auxiliary components installed. He also visited the Loco Frame Shop, which fabricates locomotive underframes using heavy fixtures, and the Engine Erection Shop, where locomotive engines are assembled. During the internship, Ramanand learned about the submerged arc, manual metal arc, and MIG welding processes used at the Heavy Welding Shop to construct locomotive components.

1. SUMMER INTERNSHIP REPORT – 2023
BANARAS LOCOMOTIVE WORKS
VARANASI – 221004
SUBMITTED TO
PRINCIPAL
TECHNICAL TRAINING CENTRE
BLW VARANASI

3. SUBMITTED BY
• Name - Ramanand Sharma
• Registration No- 2023061248
• Training duration - From 01/06/2023 to 28/06/2023 weeks
• Course - B.Tech
• Branch Name - Mechanical Engineering
• Year – 3rd year (6th Semester)
• College Name- IET ,Ayodhya , Uttar Pradesh

4. LOCO DIVISION

5. INTRODUCTION
• Loco division engaged in manufacturing of -
Electric Locomotives & HHP Diesel Locomotives
• Divisions Consist of-
1- Loco Frame Shop 5- Traction Assembly Shop
2- Truck Machine Shop 6- Loco Assembly Shop
3- Pipe Shop 7- Paint Shop
4- Sheet Metal Shop 8- Loco Test Shop

6. LOCO ASSEMBLY SHOP
• Final assembly of Electric locomotive is done in Loco Assembly
Shop.
• In electric loco shell-
Propulsion system and auxiliary assembly and devices such as-
Transformer, Auxiliary Convertor
Traction Convertor MR Blower
Roof Assembly TMB Blower assembly
These all electric connections are applied.
Then Loco wheeled up cab and machine door, pipings,
miscellaneous fittings and connections are applied.

7. LOCAL ASSEMBLY SHOP

8. LOCO FRAME SHOP
• Under-frames are fabricated using heavy fixtures and
positioners to ensure down hand welding to achieve designed
weld strength.
• Critical welds are tested radio-graphically. Welder training and
their technical competence are periodically reviewed.
• Loco Frame Shop is equipped with modern paint booth along
with remote controlled hydraulic trolley for movement of under-
frames.
• Electric loco shell is fabricated using-
Central Underframe Centre sill
Bolster side sill Buffer, driver cab
Draft gear Ductings

9. UNDER FABRICATION & PAINT BOOTH

10. ENGINE DIVISION

11. ENGINE ERECTION SHOP
• Assembly of Engine is carried out on four stations in this shop.
• Component like Crank Shaft, Cam Shaft, OST Shaft, Oil pan, Power
Assembly, Turbo Super Charger, Exhaust Manifold etc. are mounted
on crankcase and oil pan.
• During assembly important parameters i.e. various clearances, gear
backlashes, Exhaust Valve setting, Injector Timing & injector rack
setting are being maintained as per design specification.
• Fabrication of Ducting assembly and its components of Electric
Locomotive is performed in Engine Erection Shop.

12. ENGINE ERECTION SHOP

13. HEAVY WELDING SHOP
• In BLW there are basically three type of welding used in HWS :-
1. Submerged arc welding
2. Manual metal arc welding
3. MIG welding
• Submerged Arc Welding
In submerged arc welding the welding process will be covered with the
flux so that it will not react with oxygen and nitrogen. It dominates other
welding processes in the maintenance and repair industry, and though
flux-cored arc welding is growing in popularity, SMAW continues to be
used extensively in the construction of steel structures and in industrial
fabrication.

14. SUBMERGED ARC WELDING

15. • MIG WELDING
MIG welding can be used for most types of metals; steel,
stainless steel, as well as aluminium.
• Aluminium has a lower melting temperature than mild steel, for
example, so you should expect that we should use a lower heat
input but in spite of this. So we have to use a higher local heat-
input but a faster welding speed than with steel to get good
fusion and penetration.

17. THANK YOU