Introduction About D

Introduction about D.L.W

Diesel Locomotive Works, Varanasi (DLW) was set up in 1961 in technical collaboration with American Locomotive Company (ALCO) of USA for manufacture of diesel-electric locomotives. DLW has since then manufactured over 4500 Locomotives. With a capacity of building 150 locomotives per year, DISEL locomotive works is today one of the world’s largest diesel locomotive manufacturer outside North America.

In 1995, Indian Railways entered into an agreement with General Motors, USA for, USA for transfer of technology for manufacture of 4000 HP microprocessor controlled, fuel-efficient freight and passenger locomotives at Diesel Locomotive Works. Series production of 4000 HP WDG4 class heavy-duty freight locomotives and WDP4 class high-speed passenger locomotives with high speed potential of 160 kmph has already started at Diesel Locomotive Works.

In addition to meeting the requirements of Indian Railways, DLW has been supplying locomotives to non-railway customers like port trust, steel plants, power plants and fertilizer plants. DLW built locomotives have also been successfully exported to Tanzania, Vietnam, Bangladesh, Sri Lanka, Myanmar and Malaysia, meeting diverse customer requirements. DLW has also successfully diversified into the field of manufacture of Diesel Generating (DG) sets of capacities up to 2.5 MW. More than 40 DG sets have been supplied to various customers including atomic power plants.

DLW has been a pioneer in setting up quality and environment management systems on Indian Railways and is certified with ISO 9001:2000 as well as ISO 14001:1996 standards.

Integrated Manufacturing

Diesel Locomotive Works, Varanasi, a production unit under the Ministry of Railways, is one of the very few factories in the World which can be truly called an integrated diesel locomotive manufacturing plant. The complete engine, under frame, superstructure, fabricated bogies and over 2000 components are manufactured under one roof starting from such basic construction materials like plates, sheets and pipes.Manufacturing activities at DLW are broadly divided into two major divisions: the Engine Division and the Vehicle Division. Machine Maintenance Division and Tooling Division directly support these manufacturing divisions. In house infrastructure of Design and Development wing, Laboratories, Production Planning wing and Materials Management wing make it is a self-contained heavy engineering plant.

DLW has a well-laid out factory, which permits uniform flow of materials, subassemblies and assemblies from one stage of manufacture to the next. Separate areas are clearly demarcated for Engine and Vehicle manufacturing divisions.

Fabrication and Machining of Engine Block

Steel plates of sizes up to 80mm thick are ultrasonically tested before precision cut by numerically controlled flame cutting machines. Fabrication of engine block is completed by submerged arc welding using semi-automatic welding machines. Down-hand welding is ensured using specially designed positioners. Special fixtures are used for making down-hand welding possible in radiographic examination. All welders are periodically tested and re-qualified for the assigned job.

he fabrication engine block is then taken up for variety of machining operations like planning, enveloping and drilling. All these operations use heavy duty planers and CNC drilling machines. V-boring of cylinder liner bores is a process requiring a high degree of precision and is undertaken using a specially designed machine. Recent addition of a Plano-milling center has provided further fillip to the quality and speed of enveloping operation. 12 Cylinder and 16 Cylinder Blocks have V-Base, whereas the 6 Cylinder Block is inline type. T

Component Manufacturing

Over 2000 components are manufactured in house at DLW. These include ALCO turbo Superchargers, lubricating oil pumps, water pumps, camshafts, cylinder heads, chrome plated cylinder Liners, connecting rods and various gears. Its well equipped machine shops have dedicated lines for Operations like turning, milling, gear hobbing, drilling, grinding and planning etc., in addition. DLW is Equipped with a variety of special purpose machines and a large number of state-of-the-art CNC Machines to ensure quality and precision. All related processes like heat treatment and induction Hardening is also carried out in-house. A completely new chrome plating shop for cylinder liners has been set up with modern infrastructure like fume extraction system and programmable logic controlled material movement system.

Bogie Manufacturing Under Frames & Superstructure

Large special purpose machines are utilized for machining cast and fabricated bogie frames. In the same work area, axle and wheel disc machining is undertaken on sophisticated CNC machines. Inner diameter of wheel disc are carefully machined with the outer diameter of axles before the wheel discs are pressed onto axles, at designated pressure, using a specially designed wheel press.

The complete bogie, including bogie frames, wheels and axles, brake rigging and traction motors is assembled before being sent onwards for locomotive assembly. Precision cutting and forming of sheet metal is utilized for manufacturing of superstructures including driver’s cab, engine hoods and compartments for housing electrical equipments.

All activities connected with pipes like pickling, bending, cutting, forming and threading of pipes of various sizes are undertaken in another well equipped area. In yet another work area, all electrical equipments are assembled in the fabricated

Engine Assembly Locomotive Assembly and Testing

The engine block, crankshaft, camshafts, cylinder liners, pistons, connecting rods, cylinder heads, exhaust manifold, turbo-supercharger and all related piping is assembled to make a complete engine. This is followed by mounting of electrical machines like traction alternator, auxiliary generator and exciter alternator. This power pack is tested for horsepower output and other parameters of engine health on computerized Engine Test Beds. Only after the engine parameters are found perfect, the power pack allowed to be moved to the locomotive assembly area. Assembled and tested engines are received in this shop from Engine Division. Also, Underframes, assembled trucks, superstructures and contractor compartments are received from respective manufacturing and assembly shops of Vehicle Division. Important alignments like crankshaft deflection, compressor alignment and Eddy Current Clutch/radiator frame alignment are done during assembly stage itself. Electrical control equipments are fitted and control cable harnessing is undertaken. The complete locomotive is thus assembled before being sent onward for final testing and spray painting.Rigorous testing of all locomotive systems is conducted as per laid down test procedures before the locomotive is taken up for final painting and dispatching.

Quality Assurance

Quality has been a crusade in DLW since its very inception. We actively inculcate the primary importance of manufacturing a quality product in all our workmen, supervisor and engineers from the day they join DLW. Each of our workmen is continually trained and retrained in quality aspects.

Modern instrumentation and machinery help the workmen in maintaining a high standard of quality. Under ISO 9002 certification scheme, all its jigs and fixtures, tools and gauges are calibrated regularly according to a carefully worked out plan. To supplement the rigorous standards of certification for DWL’s vendors, almost all bought-out items are subjected to quality checks and are certified by incoming inspection. DLW is the proud owner of ISO 9002w certificate for the entire manufacturing activities.

Design Capabilities & Future Plans

DLW has a modern design and development wing having Unigraphics 3D modeling and AUTOCAD work stations along with finite element analysis facilities.DLW is therefore able to design and manufacture locomotives incorporating specific customer requirements. DLW has now diversified into high powers DG sets of 2-2.5 MW range. These DG sets have micro-processor controlled governor, turbine motor air starter; solid state protection relays microprocessor based control and diagnostic system. These sets are capable of automatic start-up within 10 seconds of power failure and have a frequency variation within ± 3% and voltage dip of 15 % and have been provided with the most modern state-of-the-art alternator with brushless type excitation system and automatic voltage regulators.

Diesel Locomotive Works has supplied 12 DG sets having micro-processor control with fault diagnostic system to Nuclear Power Corporation of India. These sets are custom designed to stringent requirements.

Products of DLW: -

1). 1350 HP METER GAUGE LOCOMOTIVE YDM4.2). 1350 HP CAPE GAUGE LOCOMOTIVE VDM4.3). 2300 HP CAPE GAUGE LOCOMOTIVE.4). 2300 HP METER GAUGE LOCOMOTIVE.5). 3000 HP CAPE GAUGE LOCOMOTIVE.6).WDG4 - 4000 HP GOODS LOCOMOTIVE.

1350 HP METER GAUGE LOCOMOTIVE YDM4

1350 HP Locomotive having cast / fabricated meter Gauge Co-Co bogie. Such locomotives have been supplied to Vietnam and Myanmar. TECHNICAL INFORMATION

Wheel Arrangement Co – Co.

Track Gauge 1000 mm.

Weight 72 t.

Overall Length 15600 mm.

Wheel Diameter 965 mm.

Gear Ratio 18: 93.

Maximum Speed 96 Kmph.

Diesel Engine ALCO, 251 D 6 Cylinder in line.

HP 1350.

Transmission Electrical AC/DC.

Brake IRAB, 1 system / 28LAV-1.

Loco Air, dynamic, parking.

Train Air / Dual (Air and Vacuum).

Fuel Tank Capacity 3000 Liters.

3000 HP CAPE GAUGE LOCOMOTIVE

Provisional Specifications3000 HP Micro Processor Controlled, Main Line, Cape Gauge Locomotive with improved Cab, under development for Mozambique Railway.

TECHNICAL INFORMATION

Wheel Arrangement Co-Co.

Track Gauge 1067 mm Cape Gauge.

Weight 114 t.

Overall Length 18632 mm.

Wheel Diameter 1000 mm.

Gear Ratio 19: 92.

Maximum Speed 100 Kmph.

Diesel Engine Type: - ALCO 251-C 16 Cylinder V- Engine.

HP 3000.

Transmission Electrical AC/DC.

Brake IRAB-1.

Loco Air, Dynamic.

Train Air.

Fuel Tank Capacity 6000 Liters.

WDG4 - 4000 HP GOODS LOCOMOTIVE

Broad Gauge freight traffic Co-Co diesel electric locomotive with 16 Cylinder 4000 HP engine, AC-AC transmission, microprocessor controlled propulsion and braking with high traction high speed cast steel trucks.

First turned out in 1999 with transfer of technology from General Motor (USA), this locomotive has exceptional fuel efficiency and very low maintenance requirements. It is specifically designed for heavy haul freight traffic requirements of Indian Railways for the 21st Century. The heart of loco Traction Control Converter uses the GTO devices (obsolete technology). Now the IGBT devices, has been introduced from Oct 2006. It is the latest technology and will be cost effective and gives higher reliability.

The locomotive power has been upgraded to 4500 BCV and the first Loco (Loco No 12114) was manufactured in May 07.

TECHNICAL INFORMATION

Installed Power 4000 HP.

Axle Load 21 T.

Gauge 1676 mm.

Wheel arrangement Co-Co.

Wheel diameter 1092 mm.

Height 4201 mm.

Width 3127 mm.

Overall Length (Over Buffer Beam) 19964mm.

Weight 126T.

Maximum tractive effort 54T.

Maximum speed 100 Kmph.

Fuel tank capacity 600 Lts.

Diesel Engine

16 Cylinder 710 G3B, 2 strokes, turbocharged after cooled.

Fuel Efficient Engine.

Injection System Direct Unit Injector.

Governor Woodward.

Compression Ratio - 16:1.

Lube Oil Sump Capacity 950 Lts.

Transmission

Electrical AC-AC.

6 Traction motor (3 in parallel per bogie).

Suspension Axle hung / taper roller bearing.

Gear Ratio - 90:17.

Truck

High adhesion HTSC (High Tensile Steel Cast) truck of bogie.

Adhesion - 0.42.

Brakes

Electronic Air Brake System.

KNORR-NYAB-Computer Controlled Braking.

Air, hand, dynamic brake.

Pure air brake.

Tool RoomIntroduction:- Tool room is the bone of the mass production unit. Tool Engineering, with the state of art machineries, IDTR is capable of designing, manufacturing an array of items viz. Jigs, Fixtures, Press Tools, Plastic Moulds, Die Casting Tools, Gauges, Machine Components, Templates, Precision Machining etc. with a high accuracy and finish. The main tools which are produced in tool room in DLW are Jigs and Fixture.

Purpose of tool room in an Industry:- The following are the purpose of Tool Room in an industry or we can say why any industry should have a Tool Room.1). Supply of tool used in different workshops according to their need.2). Manufacturing of tools.3). Maintenance of tools.4). Repairing of tools.5). Testing of tools which are imported from other industries and self manufactured.6). Issuing authority of tools. Basically Jigs and Fixture are manufactured in tool room of DLW and mostly are imported from respected industries. There are different sections where tool manufacturing, testing, maintenance, finishing, etc. are done in tool room.

Sections: - Tool Room of DLW consists of following sections.1). Grinding Section.2). Pneumatic Section.3). Machining Section.4). Breakdown and Maintenance section.5). Jigs and Fixture Section.

A). Grinding Section:- Grinding Section is mainly used for the tool manufacture and grinding of them. It is also used to grind the parts of locomotive. Machines used in grinding section are Surface Grinding CNC Machine, Internal Grinding Machine, External Grinding Machine, Thread Grinding Machine etc.

Specification of Machines in Grinding Section:- The specification of Machines used in Tool Room Grinding Section is described below. Surface Grinding CNC Machine

Coolant – Water + Cutting Oil.Grinding Wheel Material – Al2O3.Grinding of Material – Mainly Mild Steel, Brass etc.Product to be Grind – Surface Grinding of any Diesel Locomotive Part.Company – Siemens (Germany).Cost – 1.20 crore.

Internal Grinding Machine

Coolant – water + cutting oil.Grinding Wheel Material - Al2O3.Chuck RPM – 6 rpm to 600 rpm.Grinding of Material – Mainly Mild Steel and High Steel.Product to be Grind – Liner, Bush, etc.Company – Hardinge (Germany).Cost- 1 crore.Grain Size of Grinding Wheel – 80, 60, 40.Grinding Wheel rpm Fix – 2910 rpm. External Grinding Machine

Coolant – water + cutting oil.Grinding Wheel Material - Al2O3.Chuck RPM – 6 rpm to 600 rpm.Grinding of Material – Mainly Mild Steel and High Steel.Product to be Grind – Liner, Bush, etc.

Company – Hardinge (Germany).Cost- 1 crore.Grain Size of Grinding Wheel – 80, 60, 40.Grinding Wheel rpm Fix – 2910 rpm. Thread Grinding Machine

Power Voltage – 400 volts, 50 Hz, 3Φ. 240 D.CControl Voltage – 95 volt, 50 Hz 240 D.CFull Load Amps – 10 A.C 30 D.CGrinding wheel Diameter – 20’’ to 15’’RPM – 1000 to 2600 rpmProduct to be Grind – Internal thread tool.Company – Jones and Lampson (USA)Amount of relief – 0.007’’.Major tool which is produced by the Thread Grinding Machine is Tap. Tap is a tool used for internal grinding.

B). Pneumatic section: -

Pneumatic means air + Pressure. The Pneumatic Section takes care of the machines which run by air pressure. All the Pneumatic machines which are to be repaired are taken to the Pneumatic Section for their repairing or replacement. In Pneumatic Section there are quite good variety pneumatic machines which are either maintained or repaired or replaced. The pressurized air comes from the air tank to the workshop of Tool Room through pipelines and this pressurized air is supplied to tool in which due to air pressure rotor runs and desired operation is obtained. Type of Pneumatic tools. a). Angle Grinder: - For Grinding. b). Drill Machine: - For Drilling. c). Dry Grinder. d). Impact Wrinch. e). Flux sweeper: - For removing flux. f). Scalar: - Used for removing flux of welding on work piece.g). Straight Grinder.

C). Brazing and Hardening Section: -

When the joining of two work piece is done above the 427 C then it is called ̊�Brazing otherwise if less than 427 C it is called soldering. In Brazing work pieces to ̊� be joined are heated while in Soldering filler material is heated. In Brazing joint is more strength full while in Soldering joint is weak. Brazing is done with the help of silver foil (Ag + Tungeston +Cd +Ni +Cu) with flux powder (Borax). Material or work piece is heated to red hot and then Brazed with silver foil and flux powder. The flux powder prevents material of work piece not to get oxidized. In Hardening Section of Tool Room Induction Hardening Machine is used for hardening of tools. First they red hot the tool with Induction Hardening Machine and then quench it in water. Induction Hardening Machine is also used for Brazing, Tempering, etc.

In Induction Hardening Machine magnetic field is induced in the material and it becomes red hot from its outer surface due to magnetic flux produced by the machine and then it is quenched.

D). Jigs and Fixture Section: -

Jigs and Fixture Section is mainly for production of Jigs, Fixture, Templates, and Gauges.

Jigs: -Jigs are used to guide the tool. Jigs are used for mainly drilling purpose and to maintain interchangeability.

Fixture: - Fixture is used to guide the job. It holds the job and guides it according to the operation of machining.There are two types of Fixtures.a). Holding Fixture.b). Welding Fixture.

Gauge: - Gauges are used for dimensional check of apparatus. The Gauges used in Tool Room area). Length Gauge.b). Snap Gauge.c). Depth Gauge.

d). Micrometer.

Templates: - Templates are used for manufacturing apparatus of accurate size, shape, and dimensions. There are two types of templates used in Tool Room.A). Marking Templates.B). Checking Templates.

E). Breakdown and Maintenance Section: - Breakdown and maintenance Section charge of the breakdown of tools and their maintenance. The tools which are blunt or are not capable of performing the desired operation are maintained and repaired in Breakdown and Maintenance Section.

F). Machine Section: - Machine Section of tool room consists of Jig boring machine, Lathe machine, Fixture boring machine, milling machine etc. for milling, boring of high accuracy.

Plant Maintenance Shop (PMS)

This shop deals with the maintenance of the machine used in the workshop such as drilling, welding machines, CNC Machines etc. The machine under continuous operation condition is liable to get some fault in its machinery. The fault could be in any part of the machine, control section or some programming problem in CNC etc. This shop does repair of such kind. This deals with repair of mostly mechanical faults.

Type of Maintenance: -1. Break down Maintenance. 2. Preventive Maintenance. In the first case of maintenance, repair can be done after the break down occur while in the second case maintenance is done on the basis of prediction checking.

Break Down Maintenance: -

Break down of machine can occur due to the following two reasons.1. Due to unpredicted failures of components which cannot be prevented.2. Due to gradual wear and tear of the parts which can elimination to a large

extent by regular inspection known a preventive that when a part should replaced, so that break down can be avoided.

Preventive Maintenance: -

Preventive maintenance is sometimes termed systematic point maintenance it is an extremely important function for the reduction of maintenance cost and to keep the good operational condition of equipment and hence increase the reliability. Preventive maintenance aim to locate the sources of trouble and to remove them before the break down occurs. Thus it is based on the idea “prevention is better than cure”. Schedule maintenance is best safe guard against costly break down to inspect lubricate and check up the equipment as frequently as possible, to take full use of equipment and to maintenance it in reliable be taken to prevent over loading, clampness, negligence and misuse of machine.

Objects: -

Preventive maintenance has following main objects: To obtain maximum availability of the plant by avoiding break down and by

reducing shut down periods to a maximum. To keep the machine in proper condition so as to maintain of the product. By minimizing the wear and tear presence the value of the plant. To ensure for the safety muff the workers. To keep the plant at maximum production efficiency. To achieve the above objective with most economical combination.

Advantage of Preventive Maintenance: -

Following are some of the important advantages of efficiently planned and will execute preventive maintenance program.

Reduction in production time.

Lesser overtime pay for maintenance personnel. Lesser number of stands by equipment is needed. Less expenditure of repairs. Due to planned spare parts replacement, lesser spare parts are needed to

remain in store all time. Greater safety to employees because of reduced break down.

Marketing Department

Works of marketing department:-

Marketing department generally deal with. Contracts Warranty

Contract:- If any product or spare part of locomotive is to sale or purchase.

Sales Purchase

Warranty:-

If any product is to be failure after sales or purchase. According to the warranty clause, the period of warranty is to be decided. Normally the period of warranty is of 90 days. After every quarter the warranty graph is to prepare. Warranty form included name of purchaser, saler value, name of part, no.

of loco, no. of part to be sale.

ACTIVITIES OF MARKETING DIVISION

Sale of locomotives, DG sets and spare to non railway customer. Single window service to the customers.

Export of locomotives and spares through intermediator like RITES and IRCON.

Settlement of warranty claims for non railways customers. Availing of credit under motivate schemes. Analysis of failure reports and initiate corrective and preventive action Payment of excise duty on sale of excisable goods and settlement of

disputed cases.

INDEXING

We mean by indexing that list or system by which any person can find easily or lastly any letter or document, like that indexing is a good direction maker. Telephone directory or any list given in the first page of any book is the example of indexing.“An index is finding tool it furnishes the key as to how, the material are arranged.”

ADVANTAGE OF INDEXING

For policy making. Advantage of proof. Settlement of mutual differences. Benefit of references. Facility in sending information-reports to the government. Security of letters and documents.

Production control

Production Work Order: - In D.L.W we are using barrel work order. Such as: - 04/000/00.

1 st Barrel : - It consists of two digits. In above work order 04 is 1st barrel no. having two digits which is the standard signification of the code of particular tube production.

2 nd Barrel : - It consists of three digits which are signifying of the Serial No. of Relay Board.

3 rd Barrel : - It consists of two digits, which are signifying the batch of relay bulk order.

Part No.: - In D.L.W Part No. consist of four barrels, such as 10120488. 1st two digits as – (10) show division.2nd two digits such as –(12) show group assembly ,3rd three digits such as –(048) show allotment of any part no. & last and 4th one digit (8) show computer or check digit.

Checking of Part No. (Correct or Not): -In above part no. 10120488, we write down left to right-8765432 & then multiply together and write for adding and again in total we divided by11.

EXAMPLE 10120488 ×8765432 8 0 10 0 12 16 T0TAL 52T is correct part no. because in divide 8 save which is last digit of the above part no.

Work order distribution of production: -

04/000/00 Engine Division (04 is only allotted for Eng. Div.)

05/000/00 Loco Division (05 is allotted only for loco div.)12/000/00 Private firm13/000/00 Private firm but Govt. under taking07/000/00 Stock suspense21/000/00 Repair assistance22/000/00 Emergency spire01/117/0001/118/00 replacement of M-13 work order02/119/0018/000/00 Annexure ‘N’14/000/00 Repair block01/117/00001/118/0001/119/00 01=non production standing work order 117=expense no. for replacement or rectification due to man fault 118=Expense no. for replacement other than man (m/c unit) 119 =expense no. for replacement or rectify of casting and other purchased items due to defective materials issued than stock.

Work Order System

Object and Scope of Costing: - The object and scope of cost accounting in D.L.W. are as under:-

1. To ascertain the cost of component and assemblies and complete engines and complete locomotives and of special jobs undertaken for departments, other railways and outsiders.

2. To ensure an effective control over the expenditure on the different elements of cost, i.e., material, labor and over-heads; and

3. To analyze and interpret cost data, high-light special features and present the same in intelligible statements, graphs, and reports for the information guidance and necessary action at the different levels.

Production Work Orders: -

A Production Work Order is in three barrels. The first barrel of two digits represents the Standing Work Order signifying the Code number for particular type of production work, the second of three digits for the serial number of the Railway Board’s bulk orders placed on D.L.W. or in the case of special Work Order the serial running number of the Special Work Order and the third of two digits for the serial number of batch within the order in the case of Board’s bulk orders or the Shop number in the case of Special Work Orders.

Special Work Orders: -

Special Work Orders are also Production Work Orders with the difference that are issued for works or jobs other than for production of locomotives e.g. Work Orders for manufacture of job for other railways, govt. dept., outsiders etc., and works chargeable to capital.Special Work Orders are also in three barrels as stated in Para 2.1 and are issued by the costing section of the accounts office on receipt of written request from the production office.For instance, the Special work Order no. 10/027/shop no. signifies-

1. The standing Work Order intended for manufacture of a job for a Railway by 10

2. The serial no. of the Special Work Order issued by the costing section by 027;and

3. The shop no. which executes the work.

Non-Production Work Orders:-

A Non-Production Work Order also consists of three barrels as for any for any Production Work Order. The first barrel of two digits represents the Standing Work Order, the second of three digits the expense or receipt number and the third of two digits the shop or department number.For instance, non-production work order no. 01/005/05 signifies-

1. The standing work order for booking of indirect expenses by shops and departments by 01;

2. The indirect expense number for clearness allowances by 005; and3. The shop number allotted for Sub-Assembly Shop by 05

The total indirect expenditure booked to various Non-Production Work Orders constitutes the overhead.