SIX WEEKS INDUSTRIAL TRAINING REPORT

CARRIED OUT AT

DIESEL LOCO MODERNISATION WORKS PATIALA

SUBMITTED TO: - SUBMITTED BY:-

M.S GILL SIR RITESH KUMAR
(H.O.D OF ELECTRICAL DEPARTMENT) 160340099

RIMT INSTITUTE OF ENGINERING AND TECHNOLOGY, MANDIGOBINDGARH

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 DECLARATION

I hereby declare that the industrial training report entitled is an authentic record of my own work
as requirement of 6 week industrial training during the period from 07- jun-2018 to 21 -July-
2018for the award of degree of B.tech (electrical engineering), RIMT-IET MANDIGOBIND
GARH under the guidance of (Mr. M.S GILL SIR)

(SIGNATURE OF STUDENT)

RITESH KUMAR

Date – 21-july-2018

Certified that the above statement made by the student is correct to the best of our knowledge
and belief.

Signatures-

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 ACKNOWLEGMENT

I am highly indebted to Mr. B.P. SINGH for providing me this wonderful opportunity of doing
training at D.M.W. PATIALA.

I am grateful to him for providing me with a great learning environment and helped me sharpen
my technical skills by assigning challenging tasks. It was wonderful working in real networks
and direct implementation of technology was a great learning.

I am also grateful to (H.O.D. ELECTRICAL, RIMT INSTITUTE OF ENGINEERING AND

TECHNOLOGY) for constantly interacting with me and guiding me in the right direction during
the entire course of my training.

NAME- RITESH KUMAR

ROLL NO. – 160340099

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Table of Contents

INTRODUCTION OF INDIAN RAILWAYS ..................................................................5

FACTS ABOUT RAILWAYS .......................................................................................6
INTRODUTION OF DMW ........................................................................................7
ROLE OF DMW IN THE GROWTH OF RAILWAYS ............................................. 8 - 10
WORKSHOP FACILITIES AVAILABLE AT DMW ......................................................10
LIGHT MACHINE SHOP ................................................................................... 11 - 12
HEAT TREATMENT SHOP .......................................................................................13
HEAVY MACHINE SHOP .................................................................................. 14 - 15
TRACTION MACHINE SHOP ............................................................................ 15 - 16
CARBON BRUSH SHOP ..........................................................................................16
LOCOMOTIVE REBUILDING SHOP................................................................... 17 - 18
BOGIE SHOP ..........................................................................................................19
POWER PACK SHOP........................................................................................ 19 - 20
HOW DOES AIR BRAKES WORK ..................................................................... 20 - 21
NEW INITIATIVES BY INDIAN RAILWAYS ....................................................... 22 - 24

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INTRODUCTION OF INDIAN RAILWAY

Railways serve the people of India since 1853. Indian Railways are the
biggest organization in our country, which is engaged in transportation. Indian Railways have
continuously influenced the social, economic, cultural and political life of the people. Some
important aspects of railways are together people from all costs, communities and religions of
trade and commerce, development of industries, influence on literature, poetry, music, films,
Indian Railways employing the very big population of India etc.

INDIAN RAILWAYS AT A GLANCE

First train moved on: April 16, 1853

First train run between: Bombay to Thane
First locomotive named: Lord Falkland

16th April, 1853...............The Beginning the first railway on Indian sub-continent ran over a
stretch of 21 miles from Bombay to Thane. The idea of a railway to connect Bombay with
Thane, Kalyan and with the Thal and Bhore Ghats inclines first occurred to Mr. George Clark,
the Chief Engineer of the Bombay Government, during a visit to Bhandup in 1843.

The first passenger train steamed out of Howrah station destined for Hooghly, a distance of 24
miles, on 15th August, 1854.

1st steam locomotive of India

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FACTS ABOUT INDIAN RAILWAYS

1. Indian railway has about 63,693 KM of track out of which broad gauge covers 45,103 km
& narrow gauge 15,178 km & rest covered by standard & dual gauge.

2. Indian railway runs about 12500 trains daily out of which no of PASSENGER train is
2670, no of EMU running daily is 325, MAIL AND EXPRESS are 1070 & no of
FREIGHT & MINED type trains are 6180.

3. The longest journey on the Indian railway is from JAMMU to KANYAKUMARI, a

distance of about 3751KM, covered by Him Sagar express in about 66 hours.

4. Indian railways first electric train runs on Feb 3, 1925 from Bombay VT to Kuala.

5. Computerized reservation system started at Delhi in 1986.

6. Indian railway has about 7800 locomotive, 40000 coaches, and 338000 wagons.

7. The manufacturing of steam loco in the country was stopped in 1972

8. Largest network of railways under single management: INDIAN RAILWAY.

9. Longest rail route in the world: Trans – Siberian express from Moscow to Vladivostok in
Russia. The express covers 9296 kms in 7 days.

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INTRODUCTION OF DMW

DMW is a state-of-the-art Production Unit of the Indian Railways having

integrated facilities to manufacture, upgrade & rehabilitate Locomotives
and extend maintenance support to the Diesel Locomotive fleet of Indian Railways by providing
high precision components and sub assemblies. Diesel Component Works (DCW) was set up at
Patiala with the laying of foundation stone on October 24, 1981 and production started in 1986.

The Midlife Rehabilitation of Diesel Locomotives was started in 1989 after a service life of 18
years. The name of DCW was changed to Diesel Loco Modernization Works (DMW) in July,
2003 to signify the modernization of Diesel Locomotives being done. DMW has, now, also
started manufacture of new Locomotives since March 2011. Two Multi Gen Set locos have also
been rolled out till March, 2014.

A view of Administrative Building

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ROLE OF DMW IN THE GROWTH OF INDIAN RAILWAYS

DMW is the prestigious Production Unit over Indian Railways engaged in

Manufacture/Rebuilding, upgradation and Modernization of Diesel Locos. DMW started
rebuilding activities with the outturn of 3 Locos and 15 Power packs in the financial year 1989-
90 and has gone on to achieve a Record Breaking Performance of 156 Locos including 75 rebuilt
locos, 80 new Locos (WDM3D/WDS6) & 01 Multi Gen Set Loco and 156 Power packs in
2013-14.

Manufacture of Ist Multi Gen Set Loco EFI fitted Locomotive

Manufacture of New WDM 3D 3300 Rebuilt 3300 HP Loco

HP Loco

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A view of Steam Engine model
1st electrical locomotive
manufactured in DMW

Manufacture of 345 types of high Manufacture of

precision and critical components WDM3A/WDM3A/WDM3D types
required for open line maintenance motorized wheel sets assly for
3100/300 HP Locos

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 Manufacture/remanufacture of high
speed bogies for WDM3D and WDM3A
Locos

WORKSHOP FACILITIES AVAILABLE AT DMW:-

Shops set up under Phase-I of the project are mainly Manufacturing Shops &
Support Shops

 Light Machine Shop  Carbon Brush Shop

 Heat Treatment Shop  Plant Maintenance Shop
 Traction Machine Shop  Tool Room
 Heavy Machine Shop  Electronics Lab
Shops set up under Phase-II are

 Loco Rebuilding Shop  Transmission Repair Shop

 Power Pack Shop  Air Brake & Pipe Shop
 Bogie Shop  Loco Testing & Paint shop
 Superstructure Shop

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 1. LIGHT MACHINE SHOP –
About 345 spare parts required by DMW and Zonal Railways for locomotive maintenance
including Connecting Rod, various types of Camshafts, Cam & Split Gears, Bull Gears, Valve
Gear Components, Equalizer Beams, Axles, Armature shafts, Gas inlet casings, etc. are
manufactured in the Light Machine Shop.

Special Purpose Machines:-

Light Machine Shop has 132 light & heavy duty machines for manufacturing of various types of
locomotives components. More than 52 machines are CNC. Important machines in LMS are;

CNC CAM GRINDING MACHINE

Various types of cam shafts can be
grounded on this machine.

CNC GEAR GRINDING MACHINE

This machine is being used for teeth
grinding of various types of gears of
diesel locomotive such as Cam Shaft
Gear, Bull Gear, Pinion and Crank Shaft
Gear.

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 CNC GEAR HOBBING MACHINE
This machine is being used for cutting of
teeth on various types of gears of diesel
locomotive such as Cam Shaft Gear, Bull
Gear, Pinion and Crank Shaft Gear.

CNC HORIZONTAL MACHINING

CENTER
It’s a 05 Axes machine. This machine is
capable to manufacture Armature Shafts,
Connecting Rod, Connecting Rod Cap, MB
Cap, Lifter Cross Head, Lifter Push Rod and
Equalizer Beams.

CNC AXLE TURNING LATHE

This machine is being used to manufacture
various types of axles. This machine is also
capable to achieve super finishing on axles
with roller burnishing attachment.

CNC VERTICAL TURNING LATHE

This machine is being used for machining
of crank shaft gear, cam shaft gear, bull
gear and back plate.

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 2. HEAT TREATMENT SHOP

Heat treatment is defined as an operation or combination of operations involving heating and

cooling of metal or metal or alloys in its solid state with the object of changing the characteristics
of the materials

OBJECTIVE:-

1 To improve mach inability

2 To change grain size
3 To relieve the stress of the metal induced during hot or cold working
4 To improve mechanical properties i.e. tensile strength hardness, ductility, shock
resistance etc.
5 To improve the electrical and magnetic properties
6 To produce a hard surface on ductile interior
7 To increase the resistance to wear heat and corrosion

View of Tempering Furnace

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 3. HEAVY MACHINE SHOP

Engine Blocks of Diesel Locomotives and Traction Motor Magnet Frames are remanufactured
and brought to as good as new standards. Precision machining of the Engine Blocks is carried
out on CNC Horizontal Boring & Milling Machine of PAMA, Italy make CNC machine after
complete welding of Engine Block at newly commissioned Robotic Welding Machine.

Special Purpose Machines:-

PAMA Machine Centre:-
Operations of Cam & Crank bore machining, Face serration milling, Liner bore machining and
Drilling & Tapping of Engine Block are done on this machine.

Robotic Welding Machine

G&L Milling Machine

Operations of Magnet frame boring, Milling, Facing, and Drilling &Tapping are done on this
machine.

PAMA Machine Centre Robotic Welding Machine

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 G&L Milling Machine

4. TRACTION MACINE SHOP

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

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 A view of Traction Machine Shop and its
activities/products

5. CARBON BRUSH SHOP :-

The Carbon Brush Shop manufactures 23 types of carbon brushes required for Traction
Generators, EMD Main Alternator, Companion Alternator, D.B. Grid Motor, Traction
Motors and Auxiliary Electrical Machines

Carbon Brushes made at DMW

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 6. LOCOMOTIVE REBUILDING SHOPS:-

Locomotive Rebuilding facilities include dismantling, repairs and reassembly of the complete
Locomotive including under frame. A manipulator has been developed for ensuring down hand
welding during the repair of under frame and chassis.

During rebuilding, Locomotive sub-assemblies are brought to as good as new condition. The
Locomotive is technologically upgraded and made more fuel-efficient with lesser maintenance
requirements. The Rebuilt Locomotive is subjected to a rigorous test schedule under simulated
full load conditions in a well-equipped test facility for better reliability in service.

Air Brake and Paint Shops constitute the supporting activity areas for Locomotive Rebuilding.
New Power & Control Cables are fitted during Rebuilding.

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A view of Loco rebuilding activities

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 7. BOGIE SHOP
Bogie Shop is primarily engaged in manufacturing and remanufacturing of High speed Bogies
for WDM3D and WDM3A Locos respectively. Bogie Shop also manufactures Motorized Wheel
Set Asslys. For Bogies of WDM3A, WDG3A and WDM3D Loco and supply to Zonal Railways
to meet their requirements against RSP items

Motorized wheel set Assly Assembled Bogie

8. POWER PACK SHOP –

Power Pack Shop is primarily engaged in assembly of new Power Packs for WDM3D and
WDM3A for rebuilt locos as well as supply to Zonal Railways to meet their requirements of
unit exchange spare power pack. Engine blocks for spare power packs to Railways are
supplied from the pool of engine blocks being received by HMS for repairs.

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 Power Pack Assly Engine Block on Manipulator

Q. HOW DOES AIR BRAKE WORK?

In order to design a system
without the shortcomings of the
straight air system,
Westinghouse invented a system
wherein each piece of railroad
rolling stock was equipped with
an air reservoir and a triple
valve, also known as a control
valve.

Unlike the straight air system,

the Westinghouse system uses
a reduction in air pressure in the train line to apply the brakes.

The triple valve is described as being so named as it performs three functions: Charging air into
an air tank ready to be used, applying the brakes, and releasing them. In so doing, it supports
certain other actions (i.e. it 'holds' or maintains the application and it permits the exhaust of brake
cylinder pressure and the recharging of the reservoir during the release). In his patent application,
Westinghouse refers to his 'triple-valve device' because of the three component valvular parts
comprising it: the diaphragm-operated poppet valve feeding reservoir air to the brake cylinder,
the reservoir charging valve, and the brake cylinder release valve. When he soon improved the
device by removing the poppet valve action, these three components became the piston valve, the
slide valve, and the graduating valve

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1. If the pressure in the train line is higher than that of the reservoir, the triple valve
connects the train line to the reservoir feed, causing the air pressure in the reservoir to
increase. The triple valve also causes the brake cylinder to be exhausted to the
atmosphere, releasing the brakes.

2. As the pressure in the train line and that of the reservoir equalize, the triple valve closes,
causing the air in the reservoir to be sealed in, and the brake cylinder is not pressurized.

3. As the pressure in the train line and that of the reservoir equalize, the triple valve closes,
causing the air in the reservoir to be sealed in, and the brake cylinder is not pressurized.

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NEW INITIATIVE BY RAILWAYS-
1. FITMENT OF ELECTRONIC FUEL INJECTION SYSTEM IN ALCO LOCOS :-

Electronic Fuel Injection technology has following advantages over simple system:
 Variable Injection Timing resulting in
improved SFC
 Elimination of large number of mechanical
components thus, reduction in maintenance
and increase in reliability.
 Lesser maintenance.
 Improvement in reliability.
 Better emission standards

2. BIO DIGESTOR TOILETS IN TRAIN COACHES

Bio-toilet has 3 anaerobic chambers that treat Human wastes effectively, and don't require
any cleaning or emptying the tank because of its unique systematic structural arrangements.
To start with the very first chamber, where in, the Human wastes arrive from the toilet's
outlet, consequently the solids drop to the bottom of the tank because of the systematic
structure of the bio-digester tank and the high graded pre residing bacteria (i.e. anaerobic
bacteria, which can survive in the absence of oxygen) rushes for their job (i.e. eating away
organic waste and decomposing entire occurring pathogens).
When this chamber is filled, the water overflows to the second chamber where more of the
same happens, except at this time most of the biological/solid/slugged matter has been left in
the first chamber. When the water overflows into the third chamber, it is almost 90% clean
and hence the final stage of digestion takes place. The treatment, the task of cleansing water
is continuously carried forward from the start to the end point, till the water exits the bio-
digester. When the treated water finally comes out from the bio-toilet, it is 98% clean and
free from entire pathogens. This water is now safe to be used for underground irrigation via
pipes buried below the surface. However, the treated water should not be used for human or
animal consumption, or for household cleaning without going through additional treatment.

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 Bio digester tanks

3. Use of LHB Coaches instead of ICF coaches-

-ICF stands for integral coach factory

-LHB stands for Link Hoffman Busch

I. The LHB coaches can travel at a higher speed. The maximum permissible speed for
LHB coaches in 160 kmph. These coaches have been tested at speeds ranging 200
kmph. While the ICF coach is permitted to travel at a maximum speed of 110 kmph.
II. The LHB coaches are anti-telescopic. These coaches do not penetrate into the
adjacent coaches in case of accidents.
III. During collision or derailment, the LHB coaches do not climb on the adjacent
coaches, due to the use of Center Buffer Coupling (CBC), instead of the dual buffer
system.
IV. The LHB coaches are 1.7 meters longer than the conventional ICF coaches. This
enhances the seating capacity of the LHB coaches.

LHB Coach
ICF coach

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4. Solar trains-
The solar panels generate about 17 units of power in a day which enables the lighting
system in the coach. Currently Railways will be installing solar panels on non-AC
coaches only

Solar train coach

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