Dmw Patiala

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Introduction to DMW

• DMW was setup in 1981 with the assistance of World bank.

• Components manufacturing started in 1986. • Production started for first time in carbon

brush shop in January1986 • It has two phases :

 Phase 1: It has production shops  Phase 2: It has rebuilding shops

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Objective of DMW

• Manufacturing and supply of high quality components and spares.

• Remanufacture of critical assemblies.

• Rebuilding locomotives and Power Pack. • Incorporating latest technological up

gradations.

• To enhance the performance of diesel locomotive.

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ASSET LIFE IN YEARS PERFORMANCE AND RELIABILITY 6 12 18 24 30 PERIODIC OVERHAULS LOCOMOTIVE REBUILDING

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Flow chart of Diesel Loco Rebuilding

Loco Stripping Power pack Traction Generator Traction motors Engine Block Magnet frame reclamation

Rewinding of TG

Rewinding of TMs

Engine block re-building

Bogies Frame repairs and furnishing Bogie assy and testing Component reclamation and Engine Assy Power pack assy

and testing

Under frame cleaning and repairs

Re-cabling, re-piping, brakes and loco assy Loco

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Light Machine Shop

• It has more than 70 CNC machines.

• It produces more than 250 components. • It has the following main sections:

i. Gear section.

ii. Cam shaft section.

iii. Connecting rod section. iv. CNC turning section.

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Heavy Machine Shop

• Complete re-treatment of engine blocks.

• Re-treatment of magnet frames of traction motors.

• Conversion of magnet frames of 2600 HP loco to suit 3100/3300 HP locos.

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Cylinder Liner Shop

Various important processes at CLS are: • Cast iron honing

• Vapour cleaning • Grit blasting

• Chrome plating • Diamond honing

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Power Pack Shop

• Dismantling, reconditioning and assembly of power pack.

• Load testing, specific fuel consumption testing and other type of testing

• It has following main sections:  Striping section

 Reconditioning section

 Turbo supercharger section  Governor room

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Bogie Shop

• Bogie is a main assembly of a diesel engine carrying its frame, wheel and axle assembly, various springs; traction motor etc.

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Loco Rebuilding Shop

• Water test of air dust cleaner

• Renewal of air filter housing and oil bath filter • Replacement of radiator and radiator fan

bearing

• Replacement of all gauges

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Designation of Diesel Locomotives

• This code is of the form(WDM3A)

[gauge][power][load][series][subtype] W = Broad Gauge Y = Meter Gauge Z = Narrow Gauge (2' 6") N = Narrow Gauge (2') D = Diesel C = DC traction A = AC traction CA = Dual-power AC/DC traction B = Battery electric (rare) M = Mixed Traffic P = Passenger G = Goods S = Shunting

L = Light Duty (Light Passenger?) (no longer in use)

U = Multiple Unit (EMU / DEMU). R = Railcar (see below)

 The series digit identifies the horsepower range of the loco

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Project Work

• To study all the components mounted on Power Pack of diesel loco and explain

complete mounting and testing procedure of power pack assembly.

• To note down all the rework done in power pack shop and quality improvement steps taken.

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Power Pack of Diesel Loco

• It is the power generating component .

• It has an engine block of 16 cylinders v shaped inline.

• The firing order of the cylinders is 1R-1L-4R-4L-7R-7L-6R-6L-8R-8L-5R-5L-2R-2L-3R-3L • Fuel injection takes place before 25 degrees

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Main components mounted on power

pack of diesel loco.

• There are approximately 500 components mounted on power pack.

• A few of important are as under: •Connecting rod

•Crank shaft •Cam shaft

•Cylinder liner •Engine block

•Piston with rings •Gudgeon pin

•After cooler • Lube oil filter • Fuel filter

• Traction alternator •Governor

•Crank case exhauster motor •Over speed trip

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Engine block

• It is received from HMS after complete retreatment.

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Piston, cylinder liner, connecting rod

• Piston is made by Federal Mogul Goetze limited Bangalore.

• Cylinder liner is made of cast iron alloy with chrome plating on inside.

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Crank Shaft and Cam Shaft

• Crank shaft is imported from China and USA • Modified cam shafts are used these days.

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Oil Catcher and Oil Damper

• A cast aluminum oil catcher is mounted on the

cylinder block and base and surrounds the periphery of the cranks shaft flange oil slinger at the power

take-off end of the engine.

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Other main components

• Cylinder head

• FIP : Fuel Injection Pump • Turbo Super Charger

• After Cooler

• OST : Over Speed Trip

• Water and Lube oil pump • Traction Alternator

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Cooling process of components

• Cylinder liner are cooled by circulating water around their periphery.

• Cooling of piston crown is done by lubricating oil.

Lube oil from main bearing goes to crank pin>big end>connecting rod>small end>gudgeon

pin>piston crown.

• Cylinder heads has cooling water jacket in which water is circulated.

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Testing of various components in

PPS

• Hydraulic Testing of Engine block. • Hydraulic Testing of Gudgeon pin. • Hydraulic Testing of Cylinder head.

• Crack detection in connecting rod on Magna flux machine.

• Backlash testing of Water and Lube oil Pump. • Testing of power pack

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Testing of Power Pack

• Check all the connection of water pipes, lube oil, fuel oil etc.

• Water and fuel oil are circulated and checked for leakages (if any)

• Pre lubrication must be done.

• Run the engine for five minutes.

• Check the engine base screen for any foreign material.

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System wise failure percentage of

2008-09

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Major up-gradations

• Fuel efficient kit

– Savings 6-7% - Rs. 600-800 thousand per annum

• Power enhancement from 2600 HP to 3300 HP

– Benefits derived:

• 3 extra coaches – earns Rs. 12 million per annum • Better acceleration- Punctuality improves

• More AC coaches with high revenue can be attached • Recorded increase of 8.9% in revenue during 01-02

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Major up-gradations-contd

.

• Retro up-gradation of Engine Block

 Retro up-gradation of blocks for higher horse power ratings by providing extra stiffeners.

• Stiffer Unit cam shaft

 Power up-gradation and reduced maintenance time DCW the only unit manufacturing unit cam shafts

• 251+ cylinder heads

 Improved water jacket design for better cooling

• Super bowl pistons with 11.75:1 CR

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Major up-gradations-contd

.

• Conversion from DC-DC to AC-DC

transmission and roller bearing suspension

– Lesser maintenance and higher reliability

• Micro-processor based governor

– Maintenance free and higher fuel efficiency

• Maintenance schedules

Trip schedule: 7days to 30 days

– Savings- 40 trips/320 hrs/Rs. 300 thousand/annum

First major schedule: 12 months to 24 months

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Further Up-gradations

• Power enhancement to 3600 HP

 Prototype engine success fully tested  Adaptation of electrics under process

• Micro-processor based propulsion control system

 GE designed system for self diagnostics and in-built safety systems

 Prototype locos under trial

• Variable fuel injection timing

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Rework done in PPS

 Lube oil strainer was not set because it was not aligned in vertical direction so gasket like

material was fitted along the periphery of strainer and bracket

• Rework was done on turbocharger support by enlarging and tapping due to its holes was out. • Ovality (0.003”) of 6th_{cylinder on right side}

crossed so cylinder was taken out from the block • Rework was done on L.O.P. by enlarging all

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Quality improvement steps taken in

PPS

• Modification in push rod assembly with pressed ends

• Use of 18mm FIP to provide more fuel. • Improved FIP tube with auto Frettage

Increases fatigue strength

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