The document provides information about training conducted at DLW Varanasi, an Indian Railways production unit that manufactures diesel-electric locomotives. It details the establishment of DLW in 1956 in collaboration with ALCO, its production of over 2000 components, and manufacturing processes for locomotive components like engines, rotors, and trucks. It also describes testing procedures for locomotives and engines including lubrication, water circulation, and load testing.

2. TRAINING AT DLW VANARASI
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Mechanical Engineering
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3. introductioN
 DLW was founded by 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 late, on January 3, 1964. It
manufactures locomotives.

4. INTRODUCTION
 DLW IS A production unit under the ministry of railway, it is one of the
factories in the world which can be called diesel locomotive
manufacturing plant .
 It had made over 2000 component s are manufactured.
 Set up in 1961 technical collaboration with ALCO of USA for manufacture
of diesel electric locomotive .
 In 1995 , Indian railway entered into an agreement with general motors
,USA is transfer this technology for manufacture of 4000hp
microprocessor controller.

5. INTRODUCTION
 Got its first ISO certification in 1997 and ISO-9001 and ISO-14001 in
December 2002.
 At present the locomotive produced by DLW; i.e. GM engine has capacity
up to 5000HP & try to make it 5500 HP.
 It has supplied locomotive to other countries such as Sri lanka ,
Bangladesh , Malaysia, Vietnam etc.
 DLW is supplied locos to PSU’s & Industries like NTPC , coal ,
INDOGULF etc.

6. SOME FACTS ABOUT DIESEL ELECTRIC LOCOMOTIVE
 DLW’S annul Production -275
 Component are manufacture -2000 component
 Cost of one LOCO -25 crore(EMD)
-15 crore (ALCO)
 Weight of one LOCO -121 ton
 Fuel consumption at full load -540 lit/hr
 Fuel consumption at idle load -40 lit/hr
 Max. Speed -160km/hr
 Dia. of wheel -1092mm

7. SOME FACTS ABOUT DIESEL ELECTRIC LOCOMOTIVE

9. Alco engine assembly

11. BLOCK

12. CRANK SHAFT

14. GM ENGINE ASSEMBLY

15. PRODUCTION SHOPS
1) BLOCK DIVISIONS
2) ENGINE DIVISIONS
3) LOCO DIVISIONS
BLOCK DIVISIONS
1. Heavy Weld Shop
2. Heavy Machine Shop

16. Engine Division
1.Engine Erection Shop
2. Engine Testing Shop
3. Light Machine Shop
4. Sub Assembly Shop
5. Rotor Shop
6. Heat Treatment Shop
7. Turbo Section

17. LOCO DIVISION
1. Loco Frame Shop
2. Pipe Shop
3. Truck Machine Shop
4. Traction assembly Shop
5. Sheet Metal Shop
6. Loco Assembly Shop
7. Loco assembly Shop
8. Loco Paint Shop
9. Loco test Shop

18. Types of Welding used in DLW
1. Shielded Metal Arc Welding (SMAW)
2. Submerged Arc Welding (SAW)
3. Gas Shielded Metal Arc Welding (MIG)
4. Flux Cored Arc Welding (FCAW)

19. 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.

20. Components of Turbocharger
 For assembly of Turbojet following parts are manufactures in rotor shop---
 1. Impeller
 2. Inducer
 3. Nose piece
 4. Stud Rotor
 5. Nut
 6. Washer
 7. Thrust Washer
 8. Key
 9. Oil Slinger

21. 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.

22. 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.
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

23. Traction motor
Since the diesel- 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 the modern power and control electronics has led
to the introduction of 3Φ AC motors.

24. TRUCK FRAME:-
This is part (called the bogie in the UK) carrying the wheels and traction
motors of the locomotive

25. ANGULAR BORING MACHINE

26. LOCO & ENGINE TEST SHOP

27. types of testing
Lubricating oil testing
 Lubrication is done for better performance of the engine parts.
 Testing is done by checking the circulation of lubricant oil.
 For rotating parts checking is done by seeing the returning path of the oil
i.e. checking not only the forward path but also the returning path.
 RR40 is used as lubricating oil.

28. 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.

29. Engine test operation sequence
 Check over speed trip of recheck 3 times.
 Check bake in nozzles and set tapped clearance.
 Inspection before fist hour performance.
 First hour performance on full load.
 Base inspection.
 Second hour performance on full load.
 Attend defects of first hour performance.
 Final base inspection.
 Check engine deficiencies.
 Engine clearance.

30. 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.