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Acknowledgment 2. Preface 3. Introduction 4. Brief History 5. Orginizational Strength 9. Our Quality Policy I owe a great many thanks to a great many people who helped and supported me during making of this reporte.

My deepest thanks to Lecturer, Mr. Rajput the Guide of the reporte for guiding and correcting various documents of mine with attention and care. I express my thanks to the Lecturer Mr. Singh, for extending his support. My deep sense of gratitude to Traning incharge Mr. Singh support and guidance. Thanks and appreciation to the helpful people for their support. I would also thank my Institution and my faculty members without whom this reporte would have been a distant reality. I also extend my heartfelt thanks to my family and well wishers.

PREFACE 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 si mply. It is rightly said practical life is far away from theoretical one We learn in class roo m can give the practical exposure or real life experience personality of no doubt they help in i mproving the.

I am st udent of third year mechanical and this report is written on the basis of practical knowled ge acquired by me d uring the period on the basis of practical knowled ge acquired by me d uring the period of practical training taken at Diesel Locomotive Works, Varanasi. This unit produces diesel electro nic locomotives and DG sets for Indian railways and ot her customers in India and Abroad.

Founded in , the DLW rolled out its first locomotive three years later, on January 3, DLW has an annual production capacity of locomotives and plans to increase it to based on the current demand. DLW locomotives have power outputs ranging from 2, horsepower 1, kW to 4, horsepower 3, kW. Varanasi, one of the oldest populated cities in the world and has a promising place in the international ground both as a hub of traditions and technology.

One side the humming of divine and holy bells of the temples brings the city to life; on other side Diesel Locomotive Works DLW Varanasi is one of the largest industrial unit in eastern part of the.

DLW catch the attention of lot of foreign tourist students to observer on going amazing locomotive manufacturing process in Varanasi. This unit generate all the Diesel Electric Locomotives. In year , the first locomotive was manufactured and it was devoted to the country. Diesel Locomotive Works, Varanasi produces only Electric Diesel locomotives and auxiliary parts of locomotives. However it is an Indian corporation but it has supplied locomotives to some foreign countries also, includes Angola, Bangladesh, Malaysia, Myanmar, Sri Lanka, Vietnam and Tanzania.

Engine section manufacture more than machinery, which comprise ALCO turbo superchargers, cylinder heads, connecting rods, camshafts, lubricating oil pumps, chrome plated cylinder liners and Vehicle section of DLW unit works on different fields that include Currently, Diesel Locomotive Works, Varanasi constructs locomotives and DG sets. It is specifically designed for heavy haul freight traffic requirements of Indian Railways for the 21st Century. It is the latest technology and will be cost effective.

First turned out in , this locomotive has exceptional fuel efficiency and very low maintenance requirements. It is specifically designed for heavy haul passenger traffic requirements for Indian Railways. The WDP4 fleet is being upgraded by provision of hotel load feature along with power upgradation to HP. The prototype will be manufactured in the year Diesel Engine 16 Cylinder G3B, 2 stroke, turbocharged? Direct Unit Injector? These are provided with two drivers cabs, one at each end. These locomotives have been supplied to Angola and Sudan.

These locos have been supplied to Malaysia, Senegal and Mali. Such locomotives have been supplied to Vietnam and Myanmar. Axle mm t This locomotive is very popular with Steel Plants and Port Trusts. These include ALCO turbo superchargers, lubricating oil pumps, cam shafts, cylinder heads, chrome plated cylinder liners, connecting rods and various gears.

Our well-equipped Machine Shops have dedicated lines for operations like turning, milling, gear hobbling, 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.

Associated manufacturing processes like heat treatment and induction hardening are 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. Electrical machines like traction alternator, auxiliary generator and exciter are thereafter coupled on the engine. The complete power pack with electrics are tested on Computerised Engine Test Beds to verify horsepower output.

Vital parameters of engine are checked to assure the quality of product. Only after the engine parameters are found perfect the power packs are cleared for application on locomotives. Component Fabrication Precision cutting and forming of sheet metal is utilised for manufacture of superstructures including drivers cab, engine hoods, and compartments for housing electrical equipment.

All activities connected with pipes like pickling, bending, cutting, forming and threading of pipes of various sizes are undertaken in another well-equipped work area. All electrical equipment is assembled in the fabricated control compartments and driver? Under frame Fabrication Under-frames are fabricated with due care to ensure designed weld strength. Requisite camber to the under-frame is provided during fabrication itself. Critical Welds areas are tested radio-graphically.

Welder training and their technical competence are periodically reviewed. EMD under-frame is fabricated using heavy fixtures, positioners to ensure down hand welding. Fixtures are used to ensure proper fitting of components and quality welding in subsequent stages. Axle and wheel disc machining is undertaken on sophisticated CNC machines. Inner diameter of wheel discs are matched with the outer diameter of axles and assembled on wheel press. The complete truck bogie , including bogie frames, wheels and axles, brake rigging and traction motors are assembled which is ready for application to locomotive.

Superstructures and contractor compartments are received from. Electrical control equipments are fitted and control cable harnessing is undertaken. The complete locomotive is thus assembled before being sent onwards for final testing and painting. Steel plates are ultrasonically tested before being precision cut by numerically controlled flame cutting machines, Plasma Cutting Machine. Fabrication of Engine Block Components after flame cutting and various machining operations are fit and tack welded before taking on rollovers.

Heavy Argon-CO2 welding is done on these rollovers. High quality of welding is done by qualified welders.

Weld joints are subjected to various tests like ultrasonic, Xrays, Visual etc. Fabrication of engine block is completed by submerged arc welding using semiautomatic welding machines. Special fixtures are used for making downhand welding possible in inaccessible areas. Critical welds are subjected to radiographic examination. All welders are periodically tested and re-qualified for the assigned. After complete welding weldment is stress relieved and marking is done for subsequent machining.

This machine performs milling, drilling, tapping and boring operations in single setting. The machine accuracy of 10 micron enables adhering to the tolerance required on engine block. Angular Boring Machine Angular boring "V" boring is done of special purpose machine.

This special purpose machine has two high precision angular boring bars. This shop deals with the matching of vario us small co mpo nents required fo r the power pack unit such as, cam shaft, co nnecting rod, liners, gears levers, F. Support, Piston pin, nuts and bo lts bushes, various shafts etc. The light machine shop divided into the following section: Econometric section Grinding section Gear section Cam shaft sect ion A.

Lathe section Liners section Drilling section Milling section. Organizational Strength A flagship production unit of Indian Railways offering complete range of products in its area of operation with annual turnover of over Crore. State of the art Design and Manufacturing facility to manufacture locomotives per annum with wide range of related products viz.

DG Sets, Loco components and sub-assemblies. Supply of spares required to maintain Diesel Locomotives and DG sets. Unbeatable trail-blazing track record in providing cost-effective, eco-friendly and reliable solutions to ever increasing transportation needs for over four decades. Fully geared to meet specific transportation needs by putting Price - Value - Technology equation perfectly right.

A large base of delighted customers among many countries viz. Myanmar, Sri Lanka, Malaysia, Vietnam, Bangladesh, Tanzania, Angola, to name a few, bearing testimony to product leadership in its category. Preventing pollution by all means including minimizing resource consumption and waste generation using cleaner technologies, material substitution and process changes. Preventing all injuries and loss of property including environmental performance through continuous safety inspections.

Striving for "Right first time" and safe working practice through system improvement and training. Enhancing Customer Satisfaction through improvement in reliability and performance of products.


summer training report on dlw varansi

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Diesel Locomotive Works, Varanasi - Mechanical Engg. (ME) Summer Industrial Training Project Report

It is overseen by the Ministry of Railways of the Government of India. Indian Railways has , kilometres 70, mi. The railways traverse the length and breadth of the country and carry over 30 million passengers and 2. It is the world's second largest commercial or utility employer, with more than 1. Indian Railways manufactures much of its rolling stock and heavy engineering components at its six manufacturing plants, called Production Units, which are managed directly by the Ministry. Over the years, Indian Railways has not only achieved self-sufficiency in production of rolling stock in the country but also exported rolling stock to other countries. Each of these six production units is headed by a General Manager, who also reports directly to the Railway Board.

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