It is a Vocational Training Report (Summer Training Report) of 4 weaks in DLW, Varanasi, which consists introduction of DLW, Varanasi and 4 shops SMS (Sheet Metal Shop), SAS (Sub Assembly Shop), TMS (Truck Machine Shop) and LFS (Loco Frame Shop).

1. VOCATIONAL TRAINING
A VOACTIONAL TRAINING REPORT
On
LOCOMOTIVE MANUFACTURING
At
DIESEL LOCOMOTIVE WORKS, VARANASI
Submitted in partial fulfillment of the
requirements for the award of the degree
Of
BACHELOR OF TECHNOLOGY
In
MECHANICAL ENGINEERING
By
SHUBHAM YADAV (BT16MEC008)
DEPARTMENT OF MECHANICAL ENGINEERING
NATIONAL INSTITUTE OF TECHNOLOGY, UTTARAKHAND
SRINAGAR (GARHWAL) – 246174 (INDIA)
ODD SEMESTER, 2018

2. CANDIDATE’S DECLARATION
I, hereby declare that the work carried out in this project entitled ‘A VOCATIONAL
TRAINING PROJECT’, is presented on behalf of partial fulfilment of the requirements for
the award of degree of “Bachelor of Technology” in Mechanical Engineering submitted to
the Department of Mechanical Engineering, National Institute of Technology, Uttarakhand,
under the guidance of Dr. PAWAN KUMAR RAKESH, ASSISTANT PROFFESOR,
Department of Mechanical Engineering.
We have not submitted the record embodied in this report for the award of any other
degree or diploma to any other institute or university.
SHUBHAM YADAV
Roll No.:- BT16MEC008
Date :
Place : Srinagar (Garhwal)

3. CERTIFICATE
This is to certify that the above statement made by the candidate is correct to the best
of my knowledge and belief.
Dr. PAWAN KUMAR RAKESH
Assistant Professor
Department of Mechanical Engineering
NIT Uttarakhand

4. 1
ACKNOWLEDGEMENT
The completion of my industrial summer training at DLW Varanasi India would have
been unsuccessful without the support and proper guidance of the personnel at the
company and at my technical institution.
First of all, I am very grateful to Mr. Ram Janm Chaubey (Principal/T.T.C.) for
permitting me to do the training at DLW Varanasi.
I am grateful to Mr. Ram Chandra Maurya (S.S.E. Sheet Metal Shop), Mr. Praveen
Verma (S.S.E. Sub Assembly Shop), Mr. Santosh Kumar Shukla (S.S.E. Truck
Machining Shop) and Mr. Bhagwan Das (S.S.E. Loco Frame Shop) for their constant
support and providing me with an opportunity to get acquainted with the industrial
atmosphere and system.
I would also like to express my sincere gratitude for all the staff members who, despite
their busy work schedule, guided me patiently for a proper understanding of the processes
and documents involved.
At last but not the least, I would like to thank my professors Dr. Sanat Agarwal (HOD –
Mechanical Engineering Department), Dr. Pawan Kumar Rakesh (Assistant Professor)
and Mr. Devesh Punera (Training & Placement cell) for providing me with the required
information, supervision and support for the successful completion of my training.
These people have invested their knowledge, time and energy into completion of my
successful practical training.

5. 2
ABSTRACT
This report is based on the practical training aspects of engineering that I learned during my
vocational training. I did my summer training from Diesel Locomotive Works, Varanasi
which manufactures the diesel locomotive engines accordance with the demand of the
clients. During my visit in plant I observed how things are actually done at practical level. I
observed various machines like cutting welding holding transporting machine etc. And I
also observed the level of safety that is followed by the workers, operators, supervisors and
engineers inside the plant. That was really a new and practical experience.

6. 3
TABLE OF CONTENTS
1. Introduction 4
1.1 Background 4
1.2 Brief history 5
1.3 Salient features 6
1.4 Product of DLW 6
2. Nomenclature of Diesel Locomotive 7
3. Production Shops 9
4. Introduction of Sheet Metal Shop 10
4.1 Machines used in SMS 10
4.2 Operations 10
5. Introduction of Sub Assembly Shop 13
6. Introduction of Truck Machine Shop 17
6.1 Machines used in TMS 17
6.2 Operations 17
7. Introduction of Loco Frame Shop 20
8. Milestones Achieved 22
9. Future Plans 22
Conclusion 23
References 24

7. 4
1. Introduction
Fig. 1.1 Diesel Locomotive Works Varanasi
1.1 Background:
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
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 general motors’ of USA for
manufacture in DLW. The production of these locomotives has now started and thus DLW
is the only manufacturer of Diesel Electric Locomotives with both ALCO and General
motors’ technologies in the world.

8. 5
1.2 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
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.
Fig 1.2 Training Centre DLW
1.3 Salient Features:

9. 6
 Annual production capacity 125 Locomotives
 Annual turn-over ₹5000 million
 Total number of staff 7223
 Workshop land 89 Hectares
 Township area 211 Hectares
 Covered area in shops 86300 Sq. m
 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
 Standby power generation capacity 3000 KW
1.4 Products 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.
 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.
 WDS6 1350 HP AC/DC & DC/DC Broad Gauge Shunting 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
 Over 2000 components are manufactured Turbo Superchargers, Cam Shafts,
Cylinder Heads, Cylinder Liners, Connecting Rods and various Gears.

10. 7
2. Nomenclature of Diesel Locomotive:
Fig. 2.1 Diesel Engine
1. The first letter (gauge)
 W-Indian broad gauge (The "W" Stands for Wide Gauge - 5 Feet)
 Y-meter gauge (The "Y" stands for Yard Gauge -3Feet)
 Z-narrow gauge (2 ft. 6 in)
 N-narrow gauge (2 ft)
2. The secondletter (motive power)
 D- Diesel
 C- DC electric
 A- AC electric
 CA- Both DC and AC
 B- Battery electric locomotives (rare)

11. 8
3. 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 Units
 R-Railcars
4. The forth letter (horse power)
 3 – over 3000HP but less than 4000HP
 4 – 4000HP
 5 – 5000 HP
5. The fifth letter (subtype)
An optional number or letter that indicates some smaller variations in the basic model
are.
 A- 100HP more
 B- 200HP more
For example: WDM3A:
 "W" means broad gauge.
 "D" means diesel motive power.
 "M" means suitable for mixed (for both goods and passenger) service.
 "3A" means the locomotive's power is 3,100 HP ('3' stands for 3000 HP, 'A' denotes
100HP more ).

12. 9
1. Production Shops :
1. Heavy Weld shop 1. Engine Erection Shop 1. Loco Frame Shop
2. Heavy Machine Shop 2. Engine Testing Shop 2. Pipe Shop
3. Light machine shop 3. Truck Machine Shop
4. Sub Assembly Shop 4. Traction Assembly Shop
5. Rotor Shop 5. Sheet Metal Shop
6. Heat Treatment Shop 6. Loco Assembly Shop
7. Loco Paint Shop
8. Loco Test Shop
Fig. 3.1
Production
Shops
Block
Divisions
Engine
Divisions
Loco
Divisions
My four week
training was
confinedto four
differentsections
1.
Sheet
Metal Shop
2.
Sub
Assembly
Shop
3.
Truck
Machining
Shop
4.
Loco Frame
Shop

13. 10
4. Introduction of Sheet Metal Shop
4.1 Machines Used in SMS:
1. CNC Shearing Machine
2. CNC Hydraulic Turret Press Punch Machine
3. Layer Cutting Machine
4. CNC Bending Machine
5. Angle Shear Machine
6. Oil Furnace
7. Axial Drilling Machine
8. MIG Welding using CO2
9. Punching Machine
10. Band Saw Machine
4.2 Operations:
 Driver Cab
 Hood Over Engine
- Engine Hood
- Cooling Hood
- DB Hood
Fig. 4.1 Angle Shear Machine

14. 11
Fig. 4.2 MIG Welding using CO2
Fig. 4.3 Band Saw Machine

15. 12
Fig. 4.4 Forging of metal rod
Fig. 4.5 CNC Shearing Machine

16. 13
5. Introduction of Sub Assembly Shop
This shop deals with following section:--
 Turbo machining section
 Cylinder head & shot blast section
 Fuel pump, Support, Cam shaft ate section
 Cylinder head
 Turbo
 Governor, Water Pump, Fan drive, Lube oil Pump, After cooler assembly section.
Cylinder Head Section:- The 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 BORING MACHINE
This machine having four spindles for boring of guide hole, air & exhaust it dimensions
are—
1. Valve inner sheet diameter 4 hole - 3.1805”-3.1815”
2. Guide hole diameter - 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 Assembly :- It 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 DoorCoverAssembly :- It is special type of main base door cover
which when the crank case exhauster failed to work.
Cam Shaft Vibration Damper Assembly :- When vibration developed on the
cam shaft will be damped by this assembly.

17. 14
Fig. 5.1
O.S.T. Housing Assembly:- This assembly controls the R.P.M. of crank shaft and
keeps it a specified limit (1000 to 11500 r.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.
Fig. 5.2

18. 15
Fuel Pump Support Assembly :- It 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.
Fig. 5.3
Crank Shaft Vibration Damper :- Damped the vibration of the crank shaft which
is developed during the power stroke of Engines as act of fly wheel of the crank shaft.
Cylinder Head Assembly :- By this assembly cylinder of the engine covered and for
the fitment of the inlet valve, exhaust valve and atomizer assembly and connection of air
inlet & exhaust outlet.
It is a hollow casing in which the water jacket of made for the circulation of the cooling
water to control the temperature of heat.

19. 16
Fig. 5.5
AccelerationControlDevice :- By 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”

20. 17
6. Introduction of Truck Machine Shop
6.1 Machines usedin TMS:
1. Heavy Duty Turning Machine
2. Automatic Turning Lathe
3. Vertical cutting Lathe Machine
4. Centre Lathe Machine
5. Milling Machine
6. Axial Drill Machine
6.2 Operations:
 Truck Assembly
 Piston Pressing in Traction Motor
Fig. 6.1 Wheels and Axle are machined on CNC Turret Lathe Machine

21. 18
Fig. 6.2 Machining of Axle
Fig. 6.3 Wheel, Bull Gear, Bearings, Suspension Tube and parts are fitted on the axle by
interference fitting by applying a load of 85-130 tonnes

22. 19
Fig. 6.4 Heavy Drilling Machine for Axle
Fig. 6.5 Axle box, Vibration Damper, Suspension coil and brake rigging
components are fitted in the frame

23. 20
7. Introduction of Loco Frame Shop
A locomotive frame is the structure that forms the backbone of
the railway locomotive, giving it strength and supporting the superstructure elements
such as a cab, boiler or bodywork. The vast majority of locomotives have had a frame
structure of some kind. The frame may in turn be supported by axles directly attached
to it, or it may be mounted on bogies (UK) / trucks (US), or a combination of the two.
The bogies in turn will have frames of their own.
Types of Frame :-
Three main types of frame on steam locomotives may be distinguished-
 Plate Frames :- These used steel plates about 1-2 in (25.4-50.8 mm) thick. They
were mainly used in Britain and continental Europe. On most locomotives the frames
would be situated within the driving wheels (“inside frames”), but some classes of
early steam locomotive and diesel shutters were constructed with “outside frames”.
Some early designs were double framed where the frame consisted of plates both
inside and outside the driving wheels. Others were sandwich frames where the frame
was constructed of wood sandwiched between two metal plates.
Fig.7.1

24. 21
 Bar Frames :- These were made of two steel bars which are usually 4-7 in
(101.5-177.8) thick. They were first used on the Bury Bar Frame locomotive during
the 1830s, and were widely used in the USA throughout the nineteenth century.
Fig. 7.2
 CaststeelBeds :- Cast steel beds were the development of the final years of
steam locomotive design in the United States. They were also exported to Britain and
Australia from the USA.
Fig. 7.3

25. 22
8. MILESTONES ACHIEVED:
 Agreement with General Motors of USA for technology transfer to
 manufacture high horse-power GT46MAC 4000HP AC/AC locomotive in
 India;
 Only country outside North-America to have this bleeding edge technology;
 Many export/repeat orders complied successfully in recent past and many
 more in the pipeline;
 supplied more than 400 locomotives to various non-railway customers;
 Emerging as a leading manufacturer of ALCO/ GM locomotives for
eveloping countries.
9. FUTURE PLANS:
 GM technology to manufacture their latest 710 series of diesel electric
 locomotives;
 To emerge as a globally competitive locomotive manufacturer;
 To develop as an export hub for ALCO/ GM locos for Asian market;
 To follow an export led growth strategy through continuous improvement
 Cost effectiveness and technology/ product up-gradation as a key to retain
global competitiveness by putting price-value-technology equation right.

26. 23
CONCLUSION
As DLW focuses not on quantity, but on quality and satisfaction of its customers. It has
always been in top of public sector companies. Last year DLW has won second consecutive
time “Best Production Unit Shield of 2017-18” of Indian Railways.
As vision of DLW is :-
“To be a world class manufacturer of reliable, cost-effective, state of the art Diesel/Electric
locomotives.”
And mission of DLW is :-
“We shall achieve our vision through
 Focus on quality for sustained and continuous improvement in reliability &
performance on the product leading to customer satisfaction.
 Developing core competence with due emphasis on innovation, human resources
development and team work.
 Achieving environmental excellence by prevention of pollution, reduction of
emissions, energy conservation and preservation of natural resources.

27. 24
References
 Notes and points told by DLW officials at different divisions.
 http://www.dlw.indianrailways.gov.in
 https://www.scribd.com
 https://www.slideshare.net
 Experienced facts and knowledge shared by staff members.
 Pictures from Google and my Phone’s Gallery.