1. AN
INDUSTRIAL TRAINING PROJECT
On
RAILWAYS DIESEL ENGINE
Completed at
DIESEL LOCOMOTIVE SHED
TUGHLAKABAD, NEW DELHI
Submitted
In partial Fulfilment of the Requirements
For the award of the Degree of
BACHELOR OF TECHNOLOGY
in
MECHANICAL ENGINEERING
Submitted by
BHEEKAM GAUR
1313240044
20/06/2016 to 16/07/016(4 weeks)
GREATER NOIDA INSTITUTE OF TECHNOLOGY
PLOT 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
2. AN
INDUSTRIAL TRAINING REPORT
AT
DIESEL LOCOMOTIVE SHED,
TUGHLAKABAD, NEW DELHI
Submitted
In partial Fulfilment of the Requirements
For the award of the Degree of
BACHELOR OF TECHNOLOGY
in
MECHANICAL ENGINEERING
Submitted by
BHEEKAM GAUR
1313240044
20/06/2016 to 16/07/016(4 weeks)
DEPARTMENT OF MECHANICAL ENGINEERING
GREATER NOIDA INSTITUTE OF TECHNOLOGY
Affiliated to Dr. A.P.J. Abdul Kalam Technical University, Lucknow, UP,
(Formerly Uttar Pradesh Technical University, Lucknow, U.P)
August-2016
3. 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). .
4. 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.
5. 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….………………………………………………
6. 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
7. 46PAC)locomotivesandfamilyof 710engineshasbeensignedwithelectro motive division
ofGENERLMOTORSofUSAformanufacture inDLW. The productionoftheselocomotiveshasnow
startedandthusDLW isthe only manufacturers ofDieselElectricLocomotiveswithbothALCO and
GeneralMotorstechnologiesinthe world.
9. 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
10. PRODUCT OFDLW:
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.
12. MATERIALCONTROLOFFICE:
Preparedmateriallist(ml) whichconsistsdiag.&qty.of each partandsentto storedepartmentsfor
purchase.
FORKLIFT TRUCK
STOREDEPARTMENT:
After receivingof ML,Store Departmentsscrutinythe ML, take
Funds&vettingfromAccountdepartment&thenissuetenders, OpenTenders& Purchase
Order issued. After Receivingof Materialinspectionhasdone by InspectionDepartment.
INSPECTIONDEPARTMENT:
After Receivingof MaterialinspectionhasdonebyInspectionDep’t.If material
isOK,thenReceiptNoteissuedbyStore Dep’tandsenttoAcct.Departmentfor
paymenttofirm.IfmaterialisnotOK,theninformingtofirmtocollectthe
rejectedmaterial.
ACCOUNTDEPARTMENT:
Checkallthepurchase,givenconcurrencefor purchase,vettthe
ML/Requisition&paymenttofirms.
14. SERVICESHOPS:
1.Maintenance Areas#1,2,3
2.ToolRoom
3.CentralTransportShop
PERSONNALDEPARTMENT:
Prepare paymentof Staff, Leave Record,PersonalRecordof everyemployee,
Housingallotment, welfare ofstaff etc.
HEALTHDEPARTMENT:
Havingfacilityof Indoor&Outdoorpatients.
CIVILDEPARTMENT:
Maintenanceof colonyquarters, upgradationof facilitiesinquarters,sanitation etc.
ELECTRICALDEPARTMENT:
Maintenanceof Lightinginquartersandinworkshop,electricalworksin locomotive etc.
TECHNICALTRANINGCENTER:
Provide trainingtoallemployeesattime totime torefreshupdate their knowledge.
RESEARCH&DEVELOPMENT:
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;
15. RECENTMILESTONES&FUTUREPLAN:
MILESTONESACHIEVED:
Transferoftechnology (TOT) -- An addedfeatherinthe cap: -
Agreement
w it hG e ne r a lM o t o r s o fU S A fo r t e c h no lo gyt r a ns fe 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.
FUTUREPLANS:
• 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.
27. DRILLINGMACHINES:
The drillingmachine isamachine toolthatproducesthe necessarycutting
actionbythe rotationof amultiple edgecuttingtool.
SHAPINGANDPLANINGMACHINES:
Bothof these machinescanmachine flatsurfaceswitha singlepoint
reciprocating,motionisappliedtoboththeworkpieceandtoolinthese machines.
MILLINGMACHINES:
A millingmachineprovidescuttingactiontoarotatingtool. Thevertical
millingmachine isusedtocut, shape,andfinishmetalobjects.
GRINDINGMACHINES
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.
28. SAFETYRULESFORMACHINETOOLS:
The followingaregeneralsafetyrules foranymachinetool:
1. Gears,pulleys,belts,couplings,endsofshaftshavingkeyways,andother
revolvingorreciprocatingpartsshouldbe guardedtoaheight of6feet above
thefloor.Theguardsshouldberemovedonly forrepairingor adjustingthe machine
andmustbe replacedbefore operatingit.
2. Safety setscrewsshouldbeusedincollarsando na llre vo lvingor
reciprocatingmembersofthe 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,orbraceletsmaybecaughtinarevolvingpartwhichcouldresult
inthe 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
29. 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 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 BOROING MACHINE
This machine having four spindles for boring of guide hole, air &
exhaust it dimensions are—
1.Valve inner sheet die 4 hole- 3.1805-3.1815
2.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 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 DOOR COVER ASSEMBLY
. 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.
O.S.T. HOUSING ASSEMBLY
30. 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 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.
ACCELERATION CONTROL DEVICE
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.
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
31. 2. Inducer 8. Key
3. 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
32. 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.
33. 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
34. 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
35. sent to the air reservoir and this is done while the air passes through a set of coiled tubes after
cooler.
36. CONCLUSION
RECENTMILESTONES&FUTUREPLAN:
MILESTONESACHIEVED:
TransferofTechnology(TOT):
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.
FUTUREPLANS:
1.GM technologytomanufacture their latest710seriesofdieselelectric locomotives;
2.Toemerge as a globallycompetitive locomotive manufacturer;
3.TodevelopasanexporthubforALCO/GM locosfor Asianmarket;
4.Tofollowanexportledgrowthstrategythroughcontinuousimprovement
5.Costeffectivenessandtechnology/productup-gradationasakeytoretain
globalcompetitivenessbyputtingprice-value-technologyequationright.
