Diesel loco modernisation works at patiala

1. SEMINAR ON
INDUSTRIAL TRAINING
AT D.M.W. PATIALA
GURU NANAK INSTITUTE OF
TECHNOLOGY
By lakhvinder singh
6312507

2. INTRODUCTION
 Railways serve the people of India since 1853.
Indian Railways are the biggest organization in
our country, which is engaged in
transportation.
 First train moved on: April 16, 1853
 First train run between: Bombay to Thane
 First locomotive named: Lord Falkland

3. D.M.W. ,PATIALA
 Diesel Loco Modernization Works.
 Earlier Name- Diesel Cargo
Works(D.C.W.)
 First Stone was laid on 24th
October,1981 by the minister of
Railways Shri Kedarnath Pandey.

4. OBJECTIVES
 Modernization of LOCO.
 Remanufacture of ALCO LOCO.
 Manufacture of Engine components.
 Upgradation of LOCO.

5. Locomotive
 A locomotive or engine is a railway vehicle that provides the motive power for
a train. The word originates from the Latin loco – "from a place", ablative
of locus, "place" + Medieval Latin motivus, "causing motion", and is a
shortened form of the term locomotive engine.
 The first successful locomotives were built by Cornish inventor Richard
Trevithick in 1804.

6. WORKSHOP LAYOUT

7. Various Shops in DMW Are: -
 P.M.S Plant Maintenance Shop
 T.R Tool Room
 L.M.S Light Machine Shop
 C.B.S Carbon Brush Shop
 H.T.S Heat Treatment Shop
 V.M.S Vehicle Maintenance Shop
 T.M.S Traction Machine Shop
 M.R.S Main Receiving Shop

8.  H.M.S Heavy Machine Shop
 C.L.S Cylinder Linear Shop
 P.P.S Power Pack Shop
 B.S Bogie Shop
 S.S.S Super Structure Shop
 L.R.S Locomotive Rebuilding Shop

9. NOMENCLATURE OF
LOCOMOTIVE
The code is of the form [gauge][power][load][series][suffix]
GUAGE- W(BROAD) Y (METRE)
Z (NARROW,2.6’) N (NARROW,2’)
POWER- D = Diesel C = DC traction
A = AC traction CA = Dual-power AC/DC
B = Battery electric (rare)
LOAD- M = Multipurpose P = Passenger
G = Goods S = Shunting
L = Light Duty (Light Passenger) R = Railcar
SERIES- 1 –over 1000 hp less than 2000hp 2-over 2000 less than 3000
3--over 3000hp less than 4000hp 4-over 4000 less than 5000
SUFFIX-A-100HP B-200HP C-300HP D-400HP
WDM3A MEANS “Broad gauge diesel powered multipurpose 3100hp loco”

10.  Heat Treatment Shop
Requisite heat treatment that is induction hardening, case carburizing etc. is
carried out in the Heat Treatment Shop to develop optimum properties in the
finished components.

11.  Heavy Machine Shop
Engine Blocks of diesel locomotives and Traction Motor Magnet Frames are
machined in this shop. Precision machining of the Blocks is carried out on
CNC Horizontal Boring & Milling Machine of PAMA, Italy make CNC
machine.

12. Engine block

13.  Traction Machine Shop
A wide variety of Traction Motors, Traction Generators and Alternators are
rewound / remanufactured in this shop. Facilities include 500 T Hydraulic
Press for shafting/deshafting, Glass Bead Blasting Machine, Vacuum
Impregnation Plant, HYT Lathe, Dynamic Balancing Machine, etc.

14. The main functions of this shop are-
 Dismantling, Reconditioning and assembly of power pack.
 Load testing, specific fuel consumption testing and other types.

15. WDG2 LOCO WDP2 LOCO
WDG4 LOCO WDP4 LOCO

16. BOGIE SHOP This shop is concerned with the manufacturing,
remanufacturing and testing of bogie. Bogie is the lower
part of the loco, which supports the engine. It is a unit
where the main power of the Locomotive is utilized.

17. Parts of a Diesel-Electric Locomotive

18. Another view

19. Diesel Engine
 This is the main power source for the locomotive.
 A diesel engine (also known as a compression-ignition engine) is an internal
combustion engine that uses the heat of compression to initiate ignition to burn
the fuel that has been injected into the combustion chamber.
 It comprises a large cylinder block, with the cylinders arranged in a straight
line or in a V.

20. Engine view

21. ENGINE DATA
 CYCLE: 4 STROKE CYCLE
 MODEL: ALCO, V –SHAPED, 16 CYL
 BORE: 9 INCHES (228 mm)
 STROKE: 10.5 inches (267 mm)
 Compression Ratio : 12.5 : 1
 HORSEPOWER (GROSS): 3300 BHP
 ENGINE SPEED: 1000 RPM (FULL LOAD)
400 RPM (IDLE)
 PISTON SPEED (MEAN): 9.89 m/sec
 Air Fuel Ratio: 13:1.
 WEIGHT (DRY ENGINE): 19026 kg

22. Main Alternator
 The diesel engine drives the main
alternator which provides the power to
move the train.
 The alternator generates AC electricity
which is used to provide power for the
traction motors mounted on the trucks
(bogies).
 In older locomotives, the alternator was a
DC machine, called a generator. .

23. Auxiliary Alternator
 Locomotives used to operate passenger trains are equipped with an auxiliary
alternator.
 This provides AC power for lighting, heating, air conditioning, dining facilities
etc. on the train.
 The output is transmitted along the train through an auxiliary power line.

24. Motor Blower
 The diesel engine also drives a motor blower.
 As its name suggests, the motor blower
provides air which is blown over the traction
motors to keep them cool during periods of
heavy work.
 The blower is mounted inside the locomotive
body but the motors are on the trucks, so the
blower output is connected to each of the
motors through flexible ducting.
 The blower output also cools the alternators.

25. Traction Motor
 Since the diesel-electric 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 modern power
and control electronics has led to the
introduction of 3-phase AC motors.
Pinion/Gear
• The traction motor drives the axle
through a reduction gear of a
range between 3 to 1 (freight) and
4 to 1 (passenger).

26. Fuel Tank
 A diesel locomotive has to carry its own fuel around with
it.
 The fuel tank is normally under the loco frame and This
huge tank in the underbelly of the locomotive holds 2,200
gallons (8,328 L) of diesel fuel.
Sand Box
• Locomotives always carry sand to assist adhesion in bad
rail conditions.
• Sand is not often provided on multiple unit trains because
the adhesion requirements are lower and there are
normally more driven axles.

27. Air Reservoirs
 Air reservoirs containing compressed air
at high pressure are required for the train
braking and some other systems on the
locomotive.
 These are often mounted next to the fuel
tank under the floor of the locomotive.
Air Compressor
• The air compressor is required
to provide a constant supply of
compressed air for the
locomotive and train brakes.

28. Radiator and Radiator Fan
 The radiator works the same way as in an automobile.
 Water is distributed around the engine block to keep the temperature within the
most efficient range for the engine.
 The water is cooled by passing it through a radiator blown by a fan driven by
the diesel engine.

29. Turbo Charging
 The amount of power obtained from a
cylinder in a diesel engine depends on how
much fuel can be burnt in it.
 The amount of fuel which can be burnt
depends on the amount of air available in the
cylinder. So, if you can get more air into the
cylinder, more fuel will be burnt and you
will get more power out of your ignition.
 Turbo charging is used to increase the
amount of air pushed into each cylinder.
 Turbocharging gives a 50% increase in
engine power.

30. Locomotive Data
General Data Of Locomotive:-
 Model No. : WDM2
 Specification : 16 cylinder V-type 4 stroke
Diesel Engine
 Type : Co-Co
 Power : 700hp, 1400hp, 2400hp
 Maximum Speed : 120 kph
 Gear Ratio : 68/18
 Compression Ratio : 16:1
 Cylinder Bore : 230mm
 Cylinder Stroke : 279mm

31. Maximum Overall Dimension :-
Height : 4185mm
Width : 3010mm
Length : 17120mm
Capacity:-
Fuel : 5000 lt
Cooling Water : 1210 lt
Lube Oil : 910 lt
Water Expansion : 155 lt
Sand : 0.4 m3

32. Wheel Base:-
 Wheel Dia : 1092mm
 Wheel Base : 12834mm
 Traction Motor : Bhel 165
 Track Gauge : 1676mm
 Brake Equipment : Vaccun/Air

33. Auxiliary Horse Power Requirement:-
Auxiliary Generator Maximum : 17HP
Exciter Maximum : 12HP
Traction Motor : 400HP
Blower at full speed : 62HP
Radiator Fan : 80HP
Expresser Unloaded at 1000 rpm : 13 HP

34. BOGI ASSEMBLY
SHOP

35. bogie assembly shop
 A bogie is a wheeled wagon or trolley. In
mechanics terms, a bogie is a chassis or
framework carrying wheels, attached to a
vehicle.
 Usually the train floor is at a level above the
bogies, but the floor of the car may be lower
between bogies.

37. Parts Of Bogi

38. Axle, Wheel & Axle Box assembly
These wheels are having wear adapted profile to RDSO drawing.

39. Journal bearings & adaptor
 The bogie frame is supported on axles through “soft primary”
suspension consisting of twelve single helical coil springs, two springs
mounted on each bearing adapter (axle box), to provide ride quality
and equalization of wheel-set loads.
 Bearing adapter are fitted with tapered roller pre-lubricated, pre
adjusted & sealed bearings.
Bearing adapter
single helical coil springs
Sealed bearings
TPU shims

40. ASSEMBLY PROCESS:
 PRESS BULL GEAR ON AXLE.
 SHIFT ABOVE ASSEMBLY AT BEARING HOUSING FITTING
STAND.
 FIT THE BEARING HOUSING AND BOLTING .
 ASSEMBLE SEAL , CAP AND TAPER ROLLER BEARING
 BOLTING .
 NOW, SHIFT THIS ASSEMBLY ON WHEEL & AXLE PRESS
MACHINE.

41.  Bogie Shop
The locomotive bogies are rebuilt with new wheel sets, suspension bearings
and remanufactured traction motors. Separate shop has been set up for
machining of wheel sets and assembly of locomotive bogies.

42. SAW Features
•High Productivity, high
amperages may be used
•Easy to de-slag
•High Quality
•Deep penetration
•Excellent mechanical
properties
•Environment friendly
•Very little fume
•No radiation
•Easy operation

44. LOCO & ENGINE TEST SHOP

45. 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.

46. 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.

47. 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.

48. Development in Diesel Locomotive
 Increase in power per Cylinder.
 Increase in overall efficiency.
 Fuel Efficient & Lube efficient Engine.
 High Adhesion Loco.
 160 Kmph Speed Of WDP2 Loco.

49. Parts in power pack shop

50. Some components

51. Stripping section in LRD shop