This document provides an overview of the Summer Training Presentation for Diesel Locomotive Works (DLW) in Varanasi, India. It discusses the history and establishment of DLW, gives facts about its production levels and locomotives, provides a diagram of diesel-electric locomotives, explains locomotive classification codes, and outlines the main production shops and divisions at DLW including Block, Engine, Loco, Maintenance Service, and Sub-Assembly.

1. Summer Training Presentation
Diesel Locomotive Works, Varanasi

2. RAJ KUMAR GOEL INSTITUTE OF TECHNOLOGY
GHAZIABAD
Varun Mishra
1603340194
7th Sem
Mechanical Engineering

3. Contents
 Introduction
 Facts about DLW, Varanasi
 Diesel Electric Locomotive Diagram
 Classification of Locomotives
 Structure of Plant
 MSS
 MA
 ES
 SAS

4. Introduction
• DLW was founded by Late railway minister Mr. Lal
Bahadur Shastri on 23 April 1956.
• 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.

5. • DLW rolled out its first locomotive three years later, on
January 3, 1964.
• With technology transfer agreement from manufacturers
such as GM-EMD, DLW today produces advance
locomotives having output range from 2600 to 4000 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.

6. Facts about DLW, Varanasi
• During the year 2017-18, 323 locomotives were manufactured
including 25 Electric locomotives and 2 locomotives converted from
Diesel to Electric.
• During the year, two old diesel locomotives were converted to
electric locomotives. It is for the first time in the world that such high
horse power locomotives have been converted from Diesel to Electric.
• Cost of one loco - 12 to 14 crore (EMD) & 8 crore (Alco).
• Weight of one Loco - 121 Ton.
• Max. Speed - 160 Km/hr.
• Fuel Consumption; At Full Load - 540 lt/hr & Idle Load - 40 lt/hr.

7. Diesel Electric Locomotive Diagram
• 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.

8. Classification of Locomotives
• Locos, except the older steam ones, have classification codes that identify them.
This code is of the form-
WDG5A “ [ gauge ][ power source ][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)
• 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)

9. • 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.)
• 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……..

10. Production Shop
Block
Division
Engine
Division
Loco
Division

11. Block Division
Heavy Weld Shop Heavy Machine
Shop

12. Engine Shop
Engine Erection
Shop
Engine Testing
Shop
Light Machine
Shop
Rotor Shop
Sub-Assembly
Shop
Heat Treatment
Shop
Turbo Section

13. Loco Division
Loco Frame
Shop
Pipe Shop
Truck
Machine Shop
Traction
Assembly Shop
Sheet Metal
Shop
Loco Assembly
Shop
Loco Paint
Shop
Loco Test Shop

14. Maintenance Service Shop(MSS)
• Maintenance, repair and overhaul involve fixing any sort of
mechanical ,plumbing or electrical device that’s becomes
out of order or broken.
• MRO may be defined as, “All actions which have the
objective of restoring an item in or to a state in which it can
perform its required function.”
MSS is divided in these parts-
A. Winding Shop
B. Electronics Shop
C. Battery Shop
D. Meter Shop

15. A. Winding Shop- In this shop winding is done in traction
motor. A traction motor is an electric motor used for
propulsion of a vehicle, such as locomotives or electric
roadway vehicle.

16. B. Electronics Lab- There is a full-fledged electronics lab to
cater to maintenance need of highly sophisticated CNC
machines and component/subassembly level trouble shooting
of PCBs, Servo Drivers and Microprocessor based controllers
and electronics units. This lab also supports other Zonal
Railways in in repair of PCBs.
Important Machines-
1. Reverse Engineering System
2. Automatic Test Equipment

17. B. Battery Shop- A Battery is a device consisting of two or more
electro-chemical cell that converts stored chemical energy
into electrical energy.

18. D. Meter Shop- Meter(in locomotive) is a device that
measure’s
the loco speed, air pressure, fuel, diesel pressure, power of
electricity etc.

19. Maintenance Area
Break Maintenance- Break down of machine can occur due
to the following two reasons:
• Due to unpredictable failure of component which cannot
be prevented.
• Due to gradual wear and tear of the parts of the machine
which can be prevented by regular inspection known as
preventive maintenance.
Preventive Maintenance-
• Also termed as “planned maintenance” or “systematic
maintenance” .

20. • An extremely important function for the reduction of the
maintenance cost and to keep the good operational
condition of equipment.
Objective of Preventive Maintenance
• To keep the machine in proper condition so as to maintain
the quality of the product.
• To ensure the safety of the workers.
• To keep the plant at the maximum production efficiency.
• To achieve the above objectives with most economical
combination

21. Engine Division
Engine division is engaged in
assembly and testing of 16cyl HHP
diesel engine and 6cyl & 16cyl
ALCO design diesel engines. Many
of the vital components are
manufactures in house & CNC
machines installed in different
shops in this division.

22. Engine Erection Shop
Assembly of engine is carried out in on 4 stations in this shop.
Pre inspected component like crankshaft, camshaft, oil pan
etc are mounted on crankcase. During assembly all the
important parameters i.e. clearance, exhaust valve setting,
injector timing etc. are being maintained as per design
specifications.

26. Sub-Assembly Shop
There are nearly 40 shops in DLW, and SAS is a one of the
important shop among them. All IC engine component of rail
engine are designed here. The main purpose of this shop is to
design and construct the IC engine parts of rail engine, such
as piston, cylinder, crank & cam shafts etc.

30. In the designing of IC engine parts many machines are
used. Some of them are-
Spindle Gang Drill Machine

31. CNC Vertical Turning Lathe