AN

INDUSTRIAL TRAINING PROJECT

On

RAILWAYS DIESEL ENGINE

Completed at

DIESEL LOCOMOTIVE SHED

TUGHLAKABAD, NEW DELHI

Submitted
In partial Fulfilment of the Requirements
For the award of the Degree of

BACHELOR OF TECHNOLOGY
in

MECHANICAL ENGINEERING
Submitted by

BHEEKAM GAUR
1313240044
20/06/2016 to 16/07/016(4 weeks)

GREATER NOIDA INSTITUTE OF TECHNOLOGY

PLOT NO. 7, K.P.2, GREATER NOIDA, UP-201310
Affiliated to Dr. A.P.J. Abdul Kalam Technical University,
Lucknow

( Formerly
Lucknow )

known as Uttar Pradesh Technical University,

AUGUST-2016

AN
INDUSTRIAL TRAINING REPORT
AT

DIESEL LOCOMOTIVE SHED,

TUGHLAKABAD, NEW DELHI
Submitted
In partial Fulfilment of the Requirements
For the award of the Degree of

BACHELOR OF TECHNOLOGY
in

MECHANICAL ENGINEERING
Submitted by

BHEEKAM GAUR
1313240044
20/06/2016 to 16/07/016(4 weeks)

DEPARTMENT OF MECHANICAL ENGINEERING

GREATER NOIDA INSTITUTE OF TECHNOLOGY

Affiliated to Dr. A.P.J. Abdul Kalam Technical University, Lucknow, UP,
(Formerly Uttar Pradesh Technical University, Lucknow, U.P)
August-2016

ACKNOWLEDGEMENT
I would since rely like to thank the employees and the officers of TKD, TUGALKABAD for their
help and support during the vocational training. Despite their busy schedules, they took time out for
us
And explained to us the various aspects of the working of the plant from the production shops.

I would sincerely like to thank Mr. Sudhir (CWI /TTC) and JANARDAN PRASAD(JE/HWS), Mr.
Vipin Srivastava (JE/HWS), Mr. Arvind Kumar(JE/HMS), Er. OM KANT (SSE/HMS) who was
instrumental in arranging the vocational training at TKD, NEW DELHI , an without whose help and
guidance the training could not have materialize.

I express my deep sense of gratitude to Mr. S.P. Singh (Principal, TTC).

ABSTRACT

The objectives of

the

practical

training are to learn

something

about industries

practically and to be familiar with the working style of a technical person to adjust
simply according to the industrial environment .

It is rightly said practical life is fara way from theoretical one. We learn in class room
can give the

practical exposerreal

life experience no doubt they help in improving

the personality of the student ,but the practical exposure in the field will help the
student in long run of life and will be able to implement the theoretical knowledge.

As apart of academic syllabus of four-year degree course in Mechanical Engineering,

every student is required to under go a practical training.
I am student of third year mechanical and this report is written on the basis of practical
knowledge acquired by me.
During the period of practical training taken at diesel locomotive.

TABLE OF CONTENTS
CHAPTER-1
Introduction to Indian Railway.
CHAPTER 2
History
CHAPTER 3
[3.1]. Conclusion..
.CHAPTER 4
[4.1]. Future scope......
[4.2].Bibliography.

CHAPTER 1
INTRODUCTIONOFINDIAN RAILWAY
Indian Railways is the state-owned railway company of India. It comes under the
Ministry of Railways. Indian Railways has one of the largest and busiest rail networks in the world,
transporting over 18 million passengers and more than 2 million tones of freight daily. Its revenue is
Rs.107.66 billion. It is the world's largest commercial employer, with more than 1.4 million
employees. It operates rail transport on 6,909 stations over a total route length of more than
63,327 kilometers (39,350 miles). The fleet of Indian railway includes over 200,000 (freight)
wagons, 50,000 coaches and 8,000 locomotives. It also owns locomotive and coach production
facilities. It was founded in 1853 under the East India Company.
Indian Railways is administered by the Railway Board. Indian Railways is divided
into 16 zones. Each zone railway is made up of a certain number of divisions. There are a total of
sixty-seven divisions. It also operates the Kolkata metro. There are six manufacturing plants of the
Indian Railways. The total length of track used by Indian Railways is about 108,805 km (67,608 mi)
while the total route length of the network is 63,465 km (39,435 mi). About 40% of the total track
kilometer is electrified & almost all electrified sections use 25,000 V AC. Indian railways uses four
rail track gauges
Indian Railways operates about 9,000 passenger trains and transports 18 million
passengers daily. Indian Railways makes 70% of its revenues and most of its profits from the freight
sector, and uses these profits to cross-subsidies the loss-making passenger sector. The Rajdhani
Express and Shatabdi Express are the fastest trains of India.

GT

46PAC)locomotivesandfamilyof

710engineshasbeensignedwithelectro

motive

division

ofGENERLMOTORSofUSAformanufacture inDLW. The productionoftheselocomotiveshasnow

startedandthusDLW isthe only manufacturers ofDieselElectricLocomotiveswithbothALCO and
GeneralMotorstechnologiesinthe world.

riefHistory:
Setupin1961asagreen-fieldprojectintechnicalcollaborationwith
ALCO/USAtoManufactureDieselElectric Locomotives.
Firstlocomotive rolledoutanddedicatedtonationinJanuary,1964.

Transfer-of-TechnologyagreementsignedwithGeneralMotors/USAin

October,95

tomanufacture state-of-the-art hightractionAC-ACdiesel locomotives.

flagship

companyofIndianRailwaysofferingcompleterangeof

flankingproductsinitsarea ofoperation.

State-of-theartDesignandManufacturingfacilitytomanufacturemore
than150locomotivesperannum

withwiderangeofrelatedproductsviz.

componentsandsub-assemblies.

Unbeatable

trail-blazing

friendlyandreliablesolutionsto

trackrecordinprovidingcost-effective,

eco-

ever-increasingtransportationneedsfor

over

threedecades.

Fullygearedtomeetspecific

transportationneedsbyputting

Price-Value-

Technologyequationperfectlyright.

large

baseofdelighted

customers

Malaysia,Vietnam,Bangladesh,Tanzania
productleadershipinitscategory.

amongmanycountries
tonameafew,bearing

viz.Sri

Lanka,

testimonyto

SALIENT FEATURE

Annual production capacity`

225 Locomotives

Annual turn-over (Rs)

Total number of staff

5000 million
7223

Workshop land
Township area

89 Hectares
211 Hectares

Covered area in shops

86300 Sq.

Covered area of other

Service buildings

73700 Sq.m

Electrical power requirement

(Average maximum demand)

3468 KVA

Electrical energy consumption

(units/year)
Stand by power generation capacity

19.8 million
3000 KW

PRODUCT OFDLW:
DLW is an integrated plant and its manufacturing facilities are flexible in nature. These can be
utilized for manufacture of different design of locomotives of various gauges suiting customer
requirements and other products. Theproduct range available is as under:

WDG4

4000HP AC/ACFreightTraffic Locomotive

WDP4

4000HPAC/AC BroadGauge HighSpeed

Locomotive

WDG3D

3400HP AC/AC BroadGauge MixedTraffic

Micro-Processor ControlledLocomotive.

WDM3C
Locomotive.
WDM3A
Locomotive.

WDP3A

3300HP AC/DCBroadGauge MixedTraffic

3100HP AC/DC BroadGauge MixedTraffic

3100HP AC/DC BroadGauge HighSpeed

Passenger Locomotive.

WDG3A

3100HP AC/DC BroadGauge FreightLocomotive.

WDM2

2600HP AC/DC BroadGauge MixedTraffic

Locomotive.

WDP1

2300HP AC/DC BroadGauge IntercityExpress

Locomotive.

WDM7

2150HP DC/DC BroadGauge MixedTraffic

Locomotive.

WDM6

1350HP DC/DC BroadGauge MixedTraffic

Locomotive.

YDM4

1350HP AC/DC & DC/DC BroadGaugeMixed

traffic Locomotive.

EXPORTLOCO

2300HP AC/DC Meter Gauge/Cape gaugeMixed

Traffic Locomotive.

Diesel GeneratingSets

800KWto2500KW

Spare Partsforengines, locomotivesandgeneratingsets.

DESIGNOFFICE:
Prepare diag.of each partandsenttoMaterialControl& informtimelyinany change
inanypartstorelative department.

3D MODELOFDIESEL LOCO MOTIVE

MATERIALCONTROLOFFICE:
Preparedmateriallist(ml) whichconsistsdiag.&qty.of each partandsentto
storedepartmentsfor purchase.

FORKLIFT TRUCK

STOREDEPARTMENT:
After receivingof ML,Store Departmentsscrutinythe ML, take
Funds&vettingfromAccountdepartment&thenissuetenders, OpenTenders& Purchase
Order issued. After Receivingof Materialinspectionhasdone by InspectionDepartment.

INSPECTIONDEPARTMENT:
After Receivingof MaterialinspectionhasdonebyInspectionDept.If material
isOK,thenReceiptNoteissuedbyStore DeptandsenttoAcct.Departmentfor
paymenttofirm.IfmaterialisnotOK,theninformingtofirmtocollectthe
rejectedmaterial.

ACCOUNTDEPARTMENT:
Checkallthepurchase,givenconcurrencefor purchase,vettthe
ML/Requisition&paymenttofirms.

PLANNINGOFFICE:
Prepare JPO,MonthlyProductionProgram,Scheduling,Processing,Rate Fixing,Issue
WorkOrders,Schedule Orders,IssueJobcard&otherproduction
Documents.PreparingDLWBudget&SenttoRlyBoard.

PROGRESSOFFICE:
After openingof workorderscollecttheprod.DocumentsfromPCOandhand over tousershop
drawthe materialfromdepot&giventoshop& handover the
readymaterialofshoptousershop/store.After completionofwork,closethe workorder.

PRODUCTIONSHOPS:
Productionshopsaredividedinthreedivisions1. BlockDivisions
2. Engine Divisions
3.LocoDivisions

BLOCKDIVISION:
1.HeavyWeldShop
2.HeavyMachine Shop

ENGINEDIVISION:
1.Engine ErectionShop
2.Engine TestingShop
3.LightMachine Shop
4.SubAssemblyShop
5.Rotor Shop
6.HeatTreatmentShop

LOCODIVISION:
1.LocoFrame Shop
2.Pipe Shop
3.TruckMachine Shop
4.TractionAssemblyShop
5.SheetMetalShop
6.LocoAssemblyShop
7.LocoPaintShop
8.LocoTestShop

SERVICESHOPS:
1.Maintenance Areas#1,2,3
2.ToolRoom
3.CentralTransportShop

PERSONNALDEPARTMENT:
Prepare paymentof Staff, Leave Record,PersonalRecordof everyemployee,
Housingallotment, welfare ofstaff etc.

HEALTHDEPARTMENT:
Havingfacilityof Indoor&Outdoorpatients.

CIVILDEPARTMENT:
Maintenanceof colonyquarters, upgradationof facilitiesinquarters,sanitation etc.

ELECTRICALDEPARTMENT:
Maintenanceof Lightinginquartersandinworkshop,electricalworksin locomotive etc.

TECHNICALTRANINGCENTER:
Provide trainingtoallemployeesattime totime torefreshupdate their knowledge.

RESEARCH&DEVELOPMENT :
1. R &Da Customer CentricActivityCommittedtoInnovationand
ContinuousImprovement;
2. HighlyskilledManpower capableof handlingcomplete R&Dactivities;
3. Asophisticateddesign centerwith modern CAD/ CAE workstations
equippedwithUnigraphicsandAnsys;
4. Back-upsupport from RDSO, a centralized R&D organization at corporate level;
5. Severalmilestonesinthepast- anenviablepedigreeviz.
a. originalALCOdesignmade 7%more fuelefficient;
b.many design improvements leading to better performance, incorporatedinthe
originalALCOdesign;
c. manynewdesignsforlocomotivessuchasWDP1,WDG2,WDP2 toname a few;

RECENTMILESTONES&FUTUREPLAN:
MILESTONESACHIEVED:
Transferoftechnology (TOT) -- An addedfeatherinthe cap: Agreement
w i t h G e n e r a l M o t o r s o f U S A f o r t e c h n o l o g y t r a n s f e r t o manufacture high
horse-powerGT46MAC4000HPAC/AClocomotive in India;
OnlycountryoutsideNorth-Americatohavethisbleedingedgetechnology Many
export/repeatorderscompliedsuccessfully inrecentpast andmany moreinthe
pipeline;Suppliedmorethan400locomotives to variousnon- railway
customers;Emergingasaleadingmanufacturer ofALCO/GM
locomotivesfordevelopingcountries.

FUTUREPLANS:

AssimilationofGMtechnologytomanufacturetheirlatest710seriesof
dieselelectriclocomotives;

Toemerge as a globallycompetitive locomotive manufacturer;

Todevelopasan exporthubfor ALCO/GM locosfor Asianmarket;

To follow an export led growth strategy through continuous improvement;

Costeffectivenessandtechnology/productup-gradationasa keytoretain
globalcompetitivenessbyputtingprice-value-technologyequationright.

WDP4,4000HPPASSENGERLOCOMOTIVE

GeneralCharacteristic
InstalledPower

4000HP

AxleLoad

19.5T

Gauge

1676mm

Wheelarrangement

A-A-II-A-A

Wheeldiameter

1092mm

Height

4201mm

Width

3127mm

OverallLength(OverBuffer

19964mm

Beam)
Weight
Maxtractiveeffort
Maximumspeed
Fueltankcapacity
LocomotiveControl

117T
27T
160Mph
4000lots
EM2000withSIBAS-16Traction
Control

WDP4-4000HPGOODS
LOCOMOTIVE

TRACTIVEEFFORT& POWERCHART

INTRODUCTIONOFHEAVYWELDINGSHOP:

In theDLW there arebasically three typeofweldingusedinHWS. The weldingquality

ofDLWisvery highquality.Afterthemachiningprocesswe cantsaythatthispiece isno
singlepiece.
1. Submergedarc welding
2. Manualmetalarc welding
3. MIGwelding

SUBMERGEDARCWELDING:
In submergedarc weldingthewelding processwill becoveredwith the fluxso
thatitwillnotreactwithoxygenandnitrogen.Because ofthe versatility ofthe
processandthesimplicity ofitsequipmentandoperation,shieldedmetalarc
weldingisoneoftheworld'smostpopularweldingprocesses.
Itdominatesotherweldingprocessesinthemaintenanceandrepairindustry, andthoughfluxcoredarcweldingisgrowinginpopularity,SMAWcontinues tobeusedextensively
intheconstructionofsteelstructuresandinindustrial
fabrication.Theprocessisusedprimarilytoweld iron
andsteels(includingstainlesssteel)butaluminum,nickeland copper alloysalso beweldedwith
thismethod.

GMAWCOMPONENTS:
1. DC or DirectCurrentpowersupply
2. Electrodeor wire feedcontroller
3. Wire drive roller assembly
4. Shieldinggassource(cylinder) & regulator
5. Manuallyheld Gun& groundclamps
6. Wire reel

MIGWEL

DING:
MIGweldingcan be usedformosttypesofmetals; steel,stainless steel,aswell
asaluminum.Butweldingaluminumisverydifferentfrom weldingmildsteel
becausealuminumisametalthatisdifferentfrom steel.So whenweweld
aluminum,wehavetouseotherparameters,othersettings.Aluminumhasa
lowermeltingtemperaturethanmildsteel,forexample,soyoushouldexpect
thatweshouldusealowerheatinputbutinspiteofthis.So wehavetousea higherlocal heat-input
butafasterwelding speedthanwith steeltoget good
fusionandpenetration.Thissoundsasifaluminiumweldingis difficult,butit's
not.Theweldingsetsthatweuseadjusttheweldingparametersautomatically, so
theweldercanconcentrate ontheweldingoperation,the movementof the weldinggunandthe
weldpool.

Dip(shortarc)transfer
Arcvoltage:15 - 22V
Current:>175A
Wirestickout:5 - 12mm
Metals:steelandsteel
alloys
Connection:dc electrode
positive
Contacttube:5mminfront
ofnozzletip

Spraytransfer
Arcvoltage:27 - 54V
Current:<200A
Wirestickout:15-20
mm
Metals:aluminium(other
metalsinflatposition)
Connection:dc electrode
positive
Contacttube:5mm
insidenozzletip

INTRODUCTIONTOLIGHTMACHINESHOP

Thisshopdealswiththe matchingofvarioussmallcomponentsrequired for thepower

packunitsuchas, camshaft,connectingrod, liners, gears,levers,F.P.Support,Pistonpin,
nutsandboltsbushes,various shaftsetc.

The lightmachineshopdividedintothe followingsection: 1.Econometric Section

2.Grindingsection
3.Gear section
4.Camshaftsection
5.A.T.L. section
6.Belchingsection
7.Connectingrodsection
8.Lathe section
9.Linerssection
10.Drillingsection
11.Millingsection

01.Econometricsection:Thissectionmanufacturingvarioussizesetc. Machine
provided:-econometric machine,do-allmachine,beltgrinding machine (for
controlshaftfeed)
02.Gear-Section:
Thissectiondealstomakingvariousgearsimpeller suchas:camshaftgear, crankshaftgear,
extensionshaftgear,impeller gear (follower &drive)and broachingMachineProvided: (a) gearhobblingmachine

(b) gearshavingmachine

(c) V.T.L.machine
(d) Radialdrillingmachine
(e) Broachingmachine
(f) Centre millM/C

03.GrindingSection:
Inthissectionthe varioussmallcomponentsare grindingasper required finishingafter
machiningoperationandeachcomponentshavinggrinding allowance
(G.A.)mainpistonpin,impellerandfuller andfollower gear,
pinvalveguide,variousstuds.Camroller, seat(V/C QX head) spider variousbushesetc.

Machineprovided:
a.
b.
c.
d.
e.
f.

cylindricalgrindingmachine
internalgrindingmachine
Centre lessgrindingmachine
threadrollingmachine
universalgrindingmachine
externalgrindingmachine

04.Camshaftsection:
Thissectionmakingcamshaft(bothB.G.& M.G.) withcompleted
machiningoperationbyvariousspecialtype of machine.InB.G.08nosper
locoandinM.G.03perloco.

MachineProvided:
1.
2.
3.
4.
5.
6.
7.
8.
9.

Centre millmachine
Autolathe machine
Gundrillmachine
Externalgrindingmachine
Lathe machine
Camgrinding machine
Radialdrillingmachine
Camangle checkingmachine
Magna fluxmachine

05.AutomaticTurretLathe(A.T.L)Section:
Thissectionmanufacturingvarioustypesof smallcomponentsfor Power packengine
suchas:

Lockspringseat(V/L&X-Hd) spewingseat.Ballend,cupendad. Screw (X-HD& V/L)

copscrewsL.A.S.retainer, springlever,F.P.inlet, PorgBkt. pistonpinliner sleeve,
bodyouter ringspicier etc.

MachineProvided:
1. M.T.L.(Bartype,chucktype)
2. U.T.L.
TheA.T.L.sectionisthevitalsectionofthisshop.Maximumsmall componentsare
manufacturinginthe section.

06.BenchingSection:
In this section the benchingoperation of theentirecomponentwhichare manufacturing
intheshoparedone here.Inthebenchingsection, there
hawinghandcuttermachiningandbeltgrindingmachine,with the half of these machine
bar removingfromallthe components.

07.Connectingrodsection:
Inthissectiontheconnectingrodismade.Allthemachiningoperations ofthe
connectingrod,completedherewiththe help of varioustypesof machine.
Theconnectingrodhastwoparts, oneiscapandother isrod. Thematerial of
theconnectingrod issteepforging. InB.G.16 perloco andinM.G.6per loco.

Maindimensions:
1.
2.
3.
4.
5.
6.

crankbore (bigbore)=6-411to6.421
pistonpinbore (smallbore) =3.998 to3.999
Distance BetweenTwo= 20.995 to21.000 bareCentre
RodThickness=3.020 to3.022
Weight= 32Kg950gramto32Kggram.
Pressure Torque =150P.S.I.

08.Lathesection:
This section deals various types tropical small components are
manufacturing.Centre lath machinesoarprovidedinthissection.
Thecomponentsare:brasssleeve,wearplate,valveguide,longstud,
shaftetc.
IndrumtypeturretlatheM/Cmanufacturingpincamroller,cupend, bushwasher etc.
09. CylinderLinerSection:
Inthissection. cyclelinermachineoperationhasdoneherebythe
varioustypeofm/cs.thematerialofthecylinderLinerisspecialCast ironandthe settheper
locoisinB.G. 16andinM.G.6cylinder.

MainDimension: 1. Length2115/16+1/64
2. Insidedia.roughhoning-9.010
3. Insidedia.finishhoning 9.015
4. outsidedia. 10.00
5. Dia.ofgroove 10.749to10.750

Machineprovided: 1.
2.
3.
4.

Shotblastmachine.
Verticalboringmachine
Autolathe machine.
Honingmachine.

5. Cylindricalgrindingmachine.

10.DrillingSection:
Inthissection dialswithvariousTypesof drilling,reaming,counter bore spot
tracingandcountersinkingoperationdone of various small components.
Thecomponentsare,F.P.support,P.R.Lighter,Xhead,ValveLever,
SpringLever,Brag,Bracket,Pin,EccLever, Upperhousingetc.

MachineProvided: 1.RadialdrillingMachine,
2. Gangdrillingmachine of multyspindledrillingmachine
3.DrillingMachine
4.Electronic drillingmachine.

11.MillingMachine: This sectionmanufacturingvarioustypesofmillingoperationofthe componentsin

differenttypesof millingmachine-

MachineProvided: 1.Verticalmillingmachine
2.Horizontalmillingmachine
3.Universalmillingmachine.

INTRODUCTIONTO MACHIN SHOP

Machineshopworkisgenerally understoodtoincludeallcold-metalworkby
whichanoperator,usingeitherpowerdrivenequipmentorhandtools,removes
aportionofthemetalandshapesittosomespecifiedform orsize.Itdoesnot
includesheetmetalworkandcoppersmithing.Thefunctionof allmachine tools
istoproducemetalpartsby changingtheshape, size, orfinishofapieceof material.The shapeofa
partmadewithamachine toolislimitedbythe typesof motionthe toolcanapply.
Standardmachine toolsare groupedinsixbasic classes:
1. LATHES
2. DRILLINGMACHINES
3. SHAPERS
4. PLANERS
5. MILLINGMACHINES
6. GRINDINGMACHINES

LATHE:
The lathe isusedforturningvariousmetalsagainstacuttingtoolthatshapesit tothe
desiredproduct. The enginelatheisamachine toolthatproducesa
cuttingactionbyrotatingtheworkpiece againstthe cuttingedge of thetool.

DRILLINGMACHINES:
The drillingmachine isamachine toolthatproducesthe necessarycutting
actionbythe rotationof amultiple edgecuttingtool.

SHAPINGANDPLANINGMACHINES:
Bothof these machinescanmachine flatsurfaceswitha singlepoint
reciprocating,motionisappliedtoboththeworkpieceandtoolinthese machines.

MILLINGMACHINES:
A millingmachineprovidescuttingactiontoarotatingtool. Thevertical
millingmachine isusedtocut, shape,andfinishmetalobjects.

GRINDINGMACHINES
Agrinder differsfromother machinesinthatitusesatoolmade of emery,
Carborundum,or similar materials. The wheel,made upof manytinycutting
points,cutswiththe entiresurface area thatcomesincontactwiththe material beingground.
Grinderscutwithagrindingaction,removingmaterialinthe formof tinyparticles.

SAFETYRULESFORMA

CHINETOOLS:
The followingaregeneralsafetyrules foranymachinetool:
1. Gears,pulleys,belts,couplings,endsofshaftshavingkeyways,andother
revolvingorreciprocatingpartsshouldbe guardedtoaheight of6feet above
thefloor.Theguardsshouldberemovedonly forrepairingor adjustingthe machine
andmustbe replacedbefore operatingit.
2. Safety s ets crew s s h o u l d b e us e d i n c o l l a r s a n d o n a l l r e v o l v i n g or
reciprocatingmembersofthe machinetoolor itsequipment.
3. Donotoperate anymachine toolwithoutproper lighting.
4. Neverattempttooperateanymachinetooluntilyoufullyunderstandhow
itworksandknowhowtostopitquickly.
5. Neverwearlooseortornclothingandsecurelonghair,sincetheseitems
canbecomecaughtinrevolvingmachineparts.Tiesshouldberemoved
andshirtsleevesshouldberolledupabovetheelbow.
6. Glovesshouldneverbewornwhenoperatingmachineryexceptwhen absolutelynecessary.
7. Alwaysstopthemachine before cleaningitortakingmeasurements of the workpiece.
8. Donot lubricate amachinewhile itisinmotion.Injuryto the operatorand damage tothe
machine mayresultfromthispractice.
9. Alwayswearsafetyglassesorgoggleswhileoperatingmachinetools.
Also,wearrespiratory protectionifoperationcreateshazardousdust.All personsin
theareawhere power toolsare beingoperatedshouldalsowear safetyeye
protectionandrespiratorsasneeded.

10.Knowwheretireextinguishersarelocatedintheshopareaandhow touse them.

11.Never wearjeweler while working around machine tools. Rings,
watches,orbraceletsmaybecaughtinarevolvingpartwhichcouldresult
inthe handbeingpulledintothe machine.
12.Avoidhorseplay.Toolsareverysharpandmachinesaremadeofhard steel.
Anaccidentalslipor fallmaycause a seriousinjury.
13.Neverusecompressedairwithoutasafety nozzletocleanmachinesor
clothing.Itwillblowsharp;dangerousmetalchipsalongdistance.
14.Never place tools or othermaterials onthemachine table.Cluttering upa
machinewithtoolsormaterialscreates unsafeworkingconditions.Usea benchor
tablenearthemachine for thispurpose.
15.Alwaysuse aragwhen handlingsharpcutterssuchasmillingcuttersand endmills.

SUB ASSEMBLY SHOP

This shop deals with following section: -1.Turbo machining section
2.Cylinder head & shot blast section
3.Fuel pump, Support, Cam shaft ate section
4.Cylinder head
5.Turbo
6.Governor, Water Pump, Fan drive, Lube oil Pump, After cooler assembly
section.

CYLINDER HEAD SECTION

The lay out of this section is product type. There are different
machines had do set up per sequence of operation of cylinder head.
A milling machine provides profile cutting and taper profile
according of the template. The tracer runs and cutter forms shaper radial drilling
machine. This machine provides for drilling tapping. Core boring operation as per
drawing

HEARALD BOROING MACHINE

This machine having four spindles for boring of guide hole, air &
exhaust it dimensions are
1.Valve inner sheet die 4 hole3.1805-3.1815
2.Guide hole die1.0625-1.0635
3.Valve sheet depth (E1, E2, A1)-0.740 to 0.745 & A24.Depth of sheet (A1 E1, E2)0.205-0.215
5.Spring sheet depth (E1, E2, E1)1.865-1.885

0.950

CONTROL SHAFT ASSEMBLY

It is a link between Governor & Fuel injector pumps by which the
mechanical power from the governor transmitted to the fuel injection pump
Racks. It means to control the amount of fuel according to the requirement of load
& speed.

EXPLOSION DOOR COVER ASSEMBLY

. It is special type of main base door cover which when the crank
case exhauster failed to work

CAM SHAFT VIBRATION DAMPER ASSEMBLY

When vibration developed on the cam shaft will be damped by this
assembly.

O.S.T. HOUSING ASSEMBLY

This assembly controls the R.P.M. of crank shaft and keeps it a
specified limit (1000 to 11500 p.m.). When OST is operated in the case 16cylinder engine the engine RPM will come in ideal but in case of 16 cylinder
engines will be stopped.

FUEL PUMP SUPPORT ASSEMBLY

It is a support of the fuel pump on which the fuel injection pump is
mounted and the power of cam shaft is transmitted to operate fuel injection pump
through the cross head lighter & to operate push rod by PRD. Lifter by which the
inlet & exhaust valve open & closed through the valve lever & yokes.

ACCELERATION CONTROL DEVICE

By this device by monopoly of the driver is controlled the air & fuel
supply is controlled by according to the fuel ratio. It is controlled the proper fuel
and air ratio.

FIG NO 4(Schematic diagram of ALCO Engine)

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.

COMPONENTS OF TURBOCHARGER
For assembly of Turbojet following parts are manufactures in rotor
shop

1. Impeller 7. Thrust Washer

2. Inducer
3. Nose piece

8. Key
9. Oil Slinger

4. Stud Rotor

10. Turbine Disc

5. Nut

11. Turbo Shaft

6. Washer

12. Lock plate

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.
2 COMPRESSOR
Compressor is the combination of impeller & inducer. Impeller is made up of Alalloy. Impeller & inducer is use for sucking of fresh air from environment

.
FIG NO (5) TURBOSUPER CHRAGER

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.
For the proper working & life of Turbocharger balancing of impeller, inducer &
turbine disc is done by help of Dynamics Balancing Machine.

2.

1.

TURBO SUPERCHARGER AND ITS WORKING

3.

PRINCIPLE

The exhaust gas discharge from all the cylinders accumulate in the common
exhaust manifold at the end of which, turbo- supercharger is fitted. The gas under pressure there
after enters the turbo- supercharger through the torpedo shaped bell mouth connector and then
passes through the fixed nozzle ring. Then it is directed on the turbine blades at increased
pressure and at the most suitable angle to achieve rotary motion of the turbine at maximum
efficiency. After rotating the turbine, the exhaust gas goes out to the atmosphere through the
exhaust chimney.
The turbine has a centrifugal blower mounted at the other end of the same shaft
and the rotation of the turbine drives the blower at the same speed. The blower connected to the
atmosphere through a set of oil bath filters, sucks air from atmosphere, and delivers at higher
velocity. The air then passes through the diffuser inside the turbo- supercharger, where the
velocity is diffused to increase the pressure of air before it is delivered from the turbosupercharger
Pressurizing air increases its density, but due to compression heat develops. It
causes expansion and reduces the density. This effects supply of high-density air to the engine.
To take care of this, air is passed through a heat exchanger known as after cooler. The after
cooler is a radiator, where cooling water of lower temperature is circulated through the tubes
and around the tubes air passes. The heat in the air is thus transferred to the cooling water and
air regains its lost density. From the after cooler air goes to a common inlet manifold connected
to each cylinder head. In the suction stroke as soon as the inlet valve opens the booster air of
higher pressure density rushes into the cylinder completing the process of super charging.
The engine initially starts as naturally aspirated engine. With the increased
quantity of fuel injection increases the exhaust gas pressure on the turbine. Thus the selfadjusting system maintains a proper air and fuel ratio under all speed and load conditions of the
engine on its own. The maximum rotational speed of the turbine is 18000/22000 rpm for the
Turbo supercharger and creates max. Of 1.8 kg/cm2 air pressure in air manifold of diesel engine,
known as Booster Air Pressure (BAP). Low booster pressure causes black smoke due to
incomplete combustion of fuel. High exhaust gas temperature due to after burning of fuel may
result in considerable damage to the turbo supercharger and other component in the engine.

FIG NO (6) TURBOSUPERCHRGER WORKING

EXPRESSOR

FIG NO (7) EXPRESSOR

In Indian Railways, the trains normally work on vacuum brakes and the diesel
locos on air brakes. As such provision has been made on every diesel loco for both vacuum and
compressed air for operation of the system as a combination brake system for simultaneous
application on locomotive and train.
In ALCO locos the exhauster and the compressor are combined into one unit and it is known
as EXPRESSOR. It creates 23" of vacuum in the train pipe and 140 PSI air pressure in the
reservoir for operating the brake system and use in the control system etc.
The expressor is located at the free end of the engine block and driven through the extension
shaft attached to the engine crank shaft. The two are coupled together by fast coupling
(Kopper's coupling). Naturally the expressor crank shaft has eight speeds like the engine crank
shaft. There are two types of expressor are, 6CD,4UC & 6CD,3UC. In 6CD,4UC expressor
there are six cylinder and four exhausters whereas 6CD,3UC contain six cylinder and three
exhausters.

WORKING OF EXHAUSTER
Air from vacuum train pipe is drawn into the exhauster cylinders
through the open inlet valves in the cylinder heads during its suction stroke.
Each of the exhauster cylinders has one or two inlet valves and two
discharge valves in the cylinder head. A study of the inlet and discharge
valves as given in a separate diagram would indicate that individual
components like
(1) plate valve outer
(2) plate valve inner
(3) spring outer

(4) spring inner etc. are all interchangeable parts.

Only basic difference is that they are arranged in the reverse
manner in the valve assemblies which may also have different size and
shape. The retainer stud in both the assemblies must project upward to
avoid hitting the piston.
The pressure differential between the available pressure in the vacuum
train pipe and inside the exhauster cylinder opens the inlet valve and air is
drawn into the cylinder from train pipe during suction stroke. In the next
stroke of the piston the air is compressed and forced out through the
discharge valve while the inlet valve remains closed. The differential air
pressure also automatically opens or close the discharge valves, the same
way as the inlet valves operate. This process of suction of air from the train
pipe continues to create required amount of vacuum and discharge the
same air to atmosphere. The VA-1 control valve helps in maintaining the
vacuum to requisite level despite continued working of the exhauster.

COMPRESSOR
The compressor is a two stage compressor with one low
pressure cylinder and one high pressure cylinder. During thefirst stage of
compression it is done in the low pressurecylinder where suction is through
a wire mesh filter. After compression in the LP cylinder air is delivered into
the discharge manifold at a pressure of 30 / 35 PSI.
Workings of the inlet and exhaust valves are similar to that of
exhauster which automatically open or close under differential air pressure.
For inter-cooling air is then passed through a radiator known as inter-cooler.
This is an air to air cooler where compressed air passes through the element
tubes and cool atmospheric air is blown on the outside fins by a fan fitted on
the expressor crank shaft.
A safety valve known as inter cooler safety valve set at 60 PSI is
provided after the inter cooler as a protection against high pressure
developing in the after cooler due to defect of valves.
After the first stage of compression and after-cooling the air is again
compressed in a cylinder of smaller diameter to increase the pressure to
135-140 PSI in the same way. This is the second stage of compression in the
HP cylinder. Air again needs cooling before it is finally sent to the air
reservoir and this is done while the air passes through a set of coiled tubes
after cooler.

CONCLUSION

RECENTMILESTONES&FUTUREPLAN:

MILESTONESACHIEVED:
TransferofTechnology(TOT):

Anaddedfeatherinthe cap:-

1.AgreementwithGeneralMotorsof USAfor technologytransferto manufacture

highhorse-power GT46MAC4000HP AC/AC locomotive in India;
2.OnlycountryoutsideNorth-America tohave thisbleedingedge technology;
3.Manyexport/repeatorderscompliedsuccessfullyinrecentpastand many more inthe
pipeline;
4.suppliedmore than400 locomotivestovariousnon-railwaycustomers;
5.Emergingasa leadingmanufacturer ofALCO/GM locomotivesfor
developingcountries.

FUTUREPLANS:
1.GM technologytomanufacture their latest710seriesofdieselelectric locomotives;
2.Toemerge as a globallycompetitive locomotive manufacturer;
3.TodevelopasanexporthubforALCO/GM locosfor Asianmarket;
4.Tofollowanexportledgrowthstrategythroughcontinuousimprovement
5.Costeffectivenessandtechnology/productup-gradationasakeytoretain
globalcompetitivenessbyputtingprice-value-technologyequationright.

BIBLIOGRAPHY
1. www.indianrailways.gov.in
2. Cris-dlw.cirs.org.in
3. www.irfca.org