It is a PPT presentation on Summer Training of 4 weaks in Diesel locomotive Works, varanasi, which contains Introduction of Diesel Locomotive Works, Varanasi and 4 shops 1. SMS (Sheet Metal Shop) 2. SAS (Sub Assembly Shop) 3. TMS (Truck Machine Shop) 4. LFS (Loco Frame Shop)

1. NATIONAL INSTITUTE OF TECHNOLOGY
UTTARAKHAND
SUMMERSUMMER TRAININGTRAINING
DIESEL LOCOMOTIvE wORKS, vARANASI
Presented by-
Shubham Yadav
BT16MEC008

2. INTRODUCTION
• DLW, was founded by Late Railway Minister Mr. Lal Bahadur
Shastri on 23 April 1956. It is spread in 300 acres area at Varanasi.
• It is a production unit owned by Indian railways, for which it
manufactures diesel–electric locomotives and its spares parts.
• To meet the increased transportation needs of the Indian Railways
it was established in collaboration with ALCO (American
Locomotive Company), USA in 1961.
• DLW rolled out its first locomotive three years later, on January
3, 1964. It manufactures locomotives.

3. • Got its first ISO certification in 1997 and ISO-9001 and ISO-14001
in December 2002.
• With technology transfer agreement from manufacturers such as GM-
EMD, DLW today produces advance locomotives having output range
from 2600 to 4000 hp.
• At present the latest locomotive produced by DLW; i.e. WDG 5 has
capacity upto 5000 HP & trying to make it 5500 HP.
• It has supplied locomotives to other countries such as Sri Lanka,
Bangladesh, Malaysia, Tanzania and Vietnam etc.
• DLW is supplying locos to PSU’s & Industries Like NTPC, COAL,
INDOGULF etc.

4. SOME FACTS ABOUT DIESEL-ELECTRIC LOCOMOTIvE
 DLW’s annual production - 250 Locos
 Cost of one loco - 12 to 14 Cr (EMD), 8 Cr (Alco)
 Weight of one Loco - 121 Ton
 Fuel Consumption; At Full Load - 540 lt/hr.
 Idle Load - 40 lt/hr.
 Max. Speed - 160 Km/hr.
 Dia of Wheel - 1092 mm
 Wheel to Wheel Distance - 1596.5 mm
 Length of Under Frame - 19962 mm

5. 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.

6. NomeNclature of locomotives
Locos, except the older steam ones, have classification codes that
identify them. This code is of the form-
WDG5A “[ gauge ][ power ][load ][ series ][ sub type ]”
tHe first letter (GauGe)
W- Indian broad gauge
Y- Meter gauge
Z- Narrow gauge(2.5 ft)
N- Narrow gauge (2 ft)

7.  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 DC and AC (Can run under both AC and DC tractions)
B- Battery electric locomotive (Rare)
tHe tHirD letter (loaD tYPe)
G- Goods
P- Passenger
M- Mixed traffic; both goods and passenger
S- Used for shunting
U- Electric Multiple Units (E.M.U.)
R- Railcars

8.  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.
 tHe fiftH letter (subtYPe)
An optional letter or number
that indicates some smaller
variations in the
basic model.
For ex: ‘A’ for 100 hp,
‘B’ for 200 hp and so on……..

9. ProDuctioN sHoPs
BLOCK DIVISION ENGINE DIVISION LOCO DIVISION
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. Turbo Section 7. Loco Paint Shop
8. Loco Test Shop

10. sHeet metal sHoP (sms)
• INTRODUCTION
Cutting and forming of metal usually performed as cold working. Sheet Metal = 0.4 to
6mm thick, Plate stock > 6 mm thick.
Advantage – High strength, good dimensional accuracy, good surface finish, economical
mass production (low cost).
SHEET METAL WORKING TERMINOLOGY
• “Punch-and-die” – Tooling to perform cutting,
bending and drawing.
• “Stamping Press” – Machine tool that performs
most sheet metal operations.
• “Stampings” – Sheet Metal Products.
Laser Cutting upto 4mm

11. SHEET-METAL CHARACTERISTICS
• Elongation – the capability of the sheet Metal to stretch without necking and
failure
• Yield-point Elongation – Lueder’s bands on Low-carbon steels and Al-Mg alloys.
Lueder’s bands can be eliminated by cold
rolling the thickness by 0.5-1.5%
• Anisotropy – Crystallographic and
mechanical fibering anisotropy.
• Grain size effect on mechanical properties.
• Testing Method – Cupping test.

12. CUTTING OPERATION-
Under Water Plasma Arc Cutting Upto 16mm

13. Sub aSSembly Shop (SaS)
This shop deals with following sections:-
•Turbo Machining Section
•Cylinder head and shot blast section
•Fuel pump support, Cam Shaft section
•Cylinder head
•Turbo
•Governor, water pump, fan drive, tube oil
pump, after cooler assembly section

14. The following assemblies are performed there-
• Control Shaft Assembly
• Explosion Door Cover Assembly
• Cam Shaft Vibration Damper Assembly
• O.S.T. Housing assembly
• Fuel Pump Support Assembly
• Crank shaft vibration Damper
• Cylinder Head Assembly
• Acceleration control valve

15. Truck machine Shop (TmS)
• In this shop I have seen that how the wheels are assembled in the truck.
• At first they shift the wheels in axle shaft with the help of load (85-130
tonnes) pressing upto exact position.
• Then the arrangement of axle and wheel assembly is mounted on the truck
(bogie) .
• Truck is made by casting or machining with iron or metal alloys.
• Now this assembly is transferred in different sections where they mount the
TRACTION MOTOR .
• And further it is forwarded into the frame section where the truck is joined
with the frame.

16. Traction Motor – Electric motor providing the primary rotational
torque of a machine, usually for conversion into linear motion.
Bogie – There are two types of bogie
Co-Co bogie – has three axles and
six wheels
Bo-Bo bogie – has two axles and
four wheels

17. Loco frame shop (Lfs)
• 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 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.

18. Types of Frame
• 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. Some
early designs were double framed where the frame consisted of plates both
inside and outside the driving wheels.
Plate Frame

19. • 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.
• Cast Steel Beds - Cast steel beds were the development of the final years of
steam locomotive design in the United States.
Bar Frames Cast Steel Beds