The document provides information about Diesel Locomotive Works (DLW) in Varanasi, India. Some key points: - DLW is a production unit owned by Indian Railways that manufactures diesel-electric locomotives. It was established in 1961 in collaboration with an American company. - DLW's annual production capacity is 200 locomotives. It produces various locomotive models for freight, passenger and mixed-use applications with power ratings ranging from 1300-5500 horsepower. - The factory has different production shops for activities like welding, machining, engine assembly, and locomotive assembly. Locomotives pass through various stages from raw material to the final testing and painting processes. -

3. INTRODUCTION
 DIESEL LOCOMOTIVE WORKS (DLW), Varanasi (India) an
ISO 9001:14001 & OHS 18001 certified production unit owned
by Indian Railways, it is a central unit of Govt. of India
(ministry of Railway).
 It was laying of foundation stone of factory by the first
president of India Late Dr. Rajendra Prasad in 1956 & Diesel
Locomotive Works came existence in 1961.
 To meet the increased transportation needs of the Indian
railways it was established in near ancient city varanasi
collaboration with ALCO( American Locomotive Company),
USA in 1961.
 First locomotive rolled out and dedicated to nation in January,
1964.

4. Got its first ISO certification in 1997 and ISO-9001 and ISO-14001
in December 2002.
State of the art Design and manufacturing facility to manufacture
200 locomotive per annum with wide range of related products viz.
DG Sets , Loco components and sub-assemblies.
A large base of delighted customers among many countries viz.
Myanmar ,sri lank, Malaysia, Vietnam, Bangladesh, Tanzania,
Angola, to name a few bearing testimony to product leadership in its
category.
At present the latest locomotive produced by DLW; i.e. WDG 5 has
capacity upto 5000 HP & trying to make it 5500 HP.
First loco realesed by late lal bahadur sastri in 1964 ,WDM2

5. SALIENT FEATURES:
Annual production capacity 200 Locomotive
Annual turn-over(Rs) 5000 million
Total number of staff 8223
Workshop land 219.997 acre
Township area 520.6 acre
Covered area in shops 30.37 acre
Covered area of other service buildings 19.13 acre
Water consumption 223.82 Lakh Litres/day
Electrical Energy Consumption 262.07 Lakh Unit / Year
Workshop 4200 KVA
Administrative Building 1500 KW
Stand by Power Generation Capacity 5625 KW

6. some facts about diesel electric locomotive
 DLW’s annual production -250
 Cost of one loco - 12 to 14 crore (EMD)
8 crore (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.
 Running speed on track -110-20 km/hr
 Dia of Wheel - 1092 mm(OD)
 Wheel to Wheel Distance - 1596.5 mm
 Length of Under Frame - 19962 mm

7. Integrated Quality, Environment, Health and Safety Policy:

8. Product of DLW:
1.WDG5 5500 HPAC/AC Freight operation
type locomotive
2. WDG4 4000 HPAC/AC Freight Traffic
Locomotive
3. WDP4 4000 HPAC/AC Broad Gauge High
Speed
4. WDG3D 3400 HPAC/AC Broad Gauge Mixed Traffic
Micro-Processor Controlled Locomotive.
5. WDP3A 3100 HPAC/DC Broad Gauge High Speed
passenger Locomotive
6. WDM2 2600 HPAC/DC Broad Gauge Mixed Traffic
Locomotive
7. YDM4 1350 HPAC/DC &DC/DC Broad Gauge Mixed
Locomotive
8. WDP4D 4400 HP ac/ac Broad Gauge High Speed
Locomotive

9. General information about some locomotive product (WDG4):
Installed Power 4000HP
Axle Load 21T
Gauge 1676mm
Wheel arrangement Co-Co
Wheel diameter 1092mm
Height 4201mm
Width 3137mm
Overall Length (Over Buffer Beam) 19964m
Weight 126T
Max tractive effort 54T
Maximum speed 100kmph
Fuel tank capacity 6000lts
Locomotive Control EM 2000 with SIBAS16 Traction Control
Gear Ratio 90:17

10. Besides the Indian Railway, it regularly exports diesel electric
locomotive and has supplied locomotives to other countries such
as Sri Lanka, Malaysia, Bangladesh, Mali, Senegal, Sudan,
Tanzania, Angola, Mozambique and Vietnam and also to a few
users within India, such as ports, large power and steel plants and
private railways.
List of locomotive supplied to Non Railway Customers;
1. SAIL
2. VSP
3. NTPC
4. SEB & OTHERS
MRAKETING STATERGY:-

11. 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.

12. In India, locomotives are classified according to their track gauge, motive power, the
work they are suited for and their power or model number. The class name includes
this information about the locomotive.it comprises 4 and 5 letters.
Classification of locos on the basis of code form
WDG5A “ [ gauge ][ power ][load ][ series ][ sub type ]”
In the first letter [Gauge]:
W-Indian Broad Gauge (5.6ft)
Y-Meter Gauge or Yard Gauge (the "Y" stands 3ft or 1000mm)
Z-Narrow Gauge (2.5ft)
N-Narrow Gauge or Toy Gauge (2ft)

13. In the second letter [Power]:
D-Diesel
C-DC Traction (can run under DC traction only)
A-AC Traction (can run under AC traction only)
CA-Both DC and AC (can run under both AC and DC tractions)
B-Battery Electric Motive (rare)
In the third letter [Load]:
G-goods
P-passenger
M-mixed Traffic (both goods and passenger)
S-Used for Shunting
U-Electric multiple units (EMU)
R-Railcars

14. In 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 3000hp but less than 4000hp.
In the fifth letter [subtype]:
An optional letter or number that indicates some smaller variations in
the basic model.
For ex: ‘A’ for 100hp,
‘B’ for 200hp and so on……..
Example: Designation of ‘WDM-3A’ mean
"W" means broad gauge
"D" means diesel motive power
"M" means suitable for both goods and passenger service
"3A" means the locomotive's power is 3,100 hp('3'stands for 3000hp
’’A' denotes 100hp more)

15. WDG5 Preliminary Locomotive Layout:

16. Specification:
Fuel tank capacity - 7500lts
Weight - 133.8ton
Length - 22.3m
Wheel arrangement - co-co
Gear ratio - 90:21

17. Production Shops
BLOCK DIVISION
ENGINE DIVISION
LOCO DIVISION

18. BLOCK DIVISION:
i. Heavy Weld Shop
ii. Heavy Machine Shop
Engine Divisions:
i. Light Machine Shop
ii. Engine Erection Shop
iii. Engine Testing Shop
iv. Sub Assembly Shop
v. Rotor Shop
vi. Heat Treatment Shop
Loco Divisions:
i. Loco Frame Shop
ii. Pipe Shop
iii. Truck Machine Shop
iv. Sheet Metal Shop
v. Traction Assembly Shop
vi. Loco Assembly Shop
vii. Loco Test Shop
viii. Loco Paint Shop

19. Production Flow Chart:
Marking
out
Cutting
To Size
CAD/
CAM
Machine
And
Machinin
g Process
cutting
Joint
Assembly
Testing
And
Evaluatio
n

20. CHEMICAL & METALLURGICAL TESTING LAB
Chemical & Metallurgical Testing is domain of material science and
engineering that studies the physical and chemical behaviour of metallic
elements, and their intermetallic compounds and their mixture before
used in manufacturing process define/calculate its various properties via
testing for good quality & safety purpose.
In DLW, Testing Lab is divided in various section like that chemical,
physical, metallography section etc.
Basic Properties of metal:
i. Physical properties
ii. Mechanical properties
iii. Chemical properties
iv. And properties like Thermal, Electrical, Magnetic

21. ENGINE ERACTION SHOP
Engine eraction shop (EES) is part of Engine Division. In EES, Eraction means built
engine with assembly different-different items of engine, In these under shop deals with
different items parts assembly and different items of engine.
In under shop two types Engine eracted;
1. ALCO 2. GM

22. DEBURRING, WASHING & PAINT SECTION
PISTON CRANK SHAFT & CYLINDER ERACTION
PISTON CRANK SHAFT & CYLINDER HEAD ERACTION
GENERATOR CAMSHAFT CONTROL SHAFT &
APPLICATION
FUEL PUMP & VALVE LEVERS

23. ERACTION SHOP OF GM

26. PRODUCTION PLANNING AND CONTROL OFFICE
Production control is the task of predicting, planning and scheduling work, taking into Account
manpower, material availability and other capacity restrictions, and cost so as to achieve proper
quality and quantity at time it is needed and then following up the schedule to see that the plan is
carried out, using whatever systems have proven satisfactory for the purpose.
Production And Planning Control Function:-
i. Planning
ii. Routing
iii. Loading
iv. Scheduling
v. Combing Function
vi. Dispatching
vii. Reporting or Follow –up.
viii. Corrective Action
ix. Inspection

27. MAINTENANCE AREA
Maintenance is the action associated with equipment repair after it is broken. Also maintenance
as follows” the work of keeping something in proper condition ;upkeep.” This would imply that
maintenance should be action taken to prevent a device or component from failing or to repair
normal equipment degradation experienced with the operation of the device to keep it in proper
working order.
In DLW maintenance area divided into two section based on machine works as LMS & HMS .
TYPES OF MAINTENANCE:
It is basically;
i. Breakdown Maintenance
ii. Preventive Maintenance
Breakdown Maintenance:
Breakdown maintenance is maintenance performed on equipment that has broken down.
Breakdown maintenance may be either planned or it can be unplanned.
Break down of machine can occur due to the following two reasons:
a. Due to unpredictable failure of component which cannot be prevented.
b. Due to gradual wear and tear of the parts of the machine which can be
prevented by regular inspection known as preventive maintenance.

28. Preventive maintenance:
Preventive maintenance (PM) is a fundamental, planned maintenance activity designed to
improve equipment life and avoid any unplanned maintenance activity.
• Also termed as “planned maintenance” or “systematic
maintenance” .
• An extremely important function for the reduction of the
maintenance cost and to keep the good operational condition
of equipment.
objective of preventive maintenance
 reducing shut down period to a maximum.
 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.

29. SUB ASSEMBELY SHOP (SAS/EES)
Wheel and Axle assembly
Brake rigging assembly
Traction motor & gear case assembly

30. Axle, wheel & Gear assembly with Traction Motor

31. LOCO PAINT SHOP
After the Loco (engine) is made they are sent for final work of painting. Loco painting is done by
spray paint. Skilled workers are employed who can make markings take shape and size under
consideration.
Fig. spray paint gun

32. In DLW, Loco Paint Shop is divided into different- different section, which under section
different -different portion painted for a specified colours.
BODERING:
Light Buiscuite, Deep Yellow colour are used for WDG4. And Dazziling white, Golden
yellow colour are used for WDP4.
FINISHING:
Pickock Blue Colour are used for WDG4. And French Blue colour are used for WDP4.
FOR TRUCK PORTION:
Black paint used in both WDG4 & WDP4.
In DLW, Two types paint are used:-
1. Enamel Paint
2. Polyvinyle Paint
For safety purpose from dust particle used glass, rubber, builder plates,cables. And resist from
dust particle, Loco is spry by EZP (EPOXY ZINC PHOSPHATE).
Epoxy Surfacer:-
It is a process in paint (epoxy paint) is used for fill up all the gaps properly.

33. Fig. paint shop

34. EXPORTED LOCOMOTIVE:-
In DLW, Figures of some standard locomotive which is exported out of country,