24-09-2014, 04:11 PM
SUMMER INTERNSHIP TRAINING REPORT-2013
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Submitted in partial fulfillment for the award of diploma of polytechnic diploma
LUBRICATION OIL SYSTEM DESIGN FOR A NEW 4-STROKES SINGLECYLINDER
ENGINE CYLINDER HEAD
The Diesel Locomotive Works (DLW) in Varanasi, India, is a production unit owned by Indian Railways that manufactures diesel-electric locomotives and its spare parts. It is the largest diesel-electric locomotive manufacturer in India.
Locally it is called as D.L.W.
It is located in the Manduadih area on the outskirts of the metropolitan city of Varanasi.
Founded in 1961, the DLW rolled out its first locomotive three years later, on January 3, 1964. It manufactures locomotives which are variants based on the original ALCO designs dating to 1960s and the GM EMD designs of the 1990s.[1] DLW has an annual production capacity of 250 locomotives and plans to increase it to 275 based on the current demand.
DLW locomotives have power outputs ranging from 2,600 horsepower (1,900 kW) to 5,500 horsepower (4,100 kW). Currently DLW is producing EMD GT46MAC and EMD GT46PAC locomotives under license from Electro-Motive Diesels (formerly GM-EMD) for Indian Railways.
ABSTRACT
Diesel Locomotive Works NE railway is a leading industrial unit in the field of periodical overhaul of rolling stock it has the unique distinction of being the industrial which has completed hundred years of glorious existence in eastern UP this workshop was established in 1903 and was named as Bengal and Assam North West railway loco and carriage workshop. Skilled workers were brought from Varanasi (U.P).
With the restructuring of Indian railways after independence, this workshop assumed an important in maintenance of passenger coaches, wagon and steam locos. Hence a major investment plan was approved by railway board in 1952 major re-organization took place between1954 to 1958. Many new shop like furnishing, wagon lifting, paint and saw mill, along with other new shops came into existence during this period.
The workshop is spread over in an area if 29.3 hectare out of which covered space is 12.6 hectare. The area of roads inside workshop is 2.3 hectare. Besides the shops there are other offices such as Jig and tool Drag office, chemical and metallurgical laboratory staff canteen, basic training centre, first and aid post, security and ministerial offices inside the workshop .The total strength of workers in the workshop is 5703. There are 737 machines in the works
OBJECTIVES-
1. Insuring compliance to out tern targets.
2. Rolling M&P breakdown within 2.5% of the total available M&P.
3. Ensuring compliance to requirements of the documented quality system & periodic verification through internal quality audits.
4. Reduction in the customer complaints.
5. Reduction in “In-Service Failure” attributable to workshop.
6. Regular training to employees to improve work environment of skills and motivation level.
7. To reduce total cost by up gradation of the technology.
CarryAwayContaminantsandDebris
Lubricant circulation systems have the benefit of carrying away internally generateddebrisandexternalcontaminantsthatgetintroducedintothesystemtoafilterwheretheycanberemoved.Lubricantsformachinesthatregularlygeneratedebrisorcontaminantssuchas automotive engines typically contain detergent and dispersantadditivestoassistindebrisandcontaminanttransporttothefilterandremoval.
ProtectAgainstWear
Lubricantspreventwearbykeepingthemovingpartsapart.Lubricantsmayalsocontainanti-wearorextremepressureadditivestoboosttheirperformanceagainstwear andfatigue.
PreventCorrosion
Good qualitylubricants are typically formulated with additives that formchemicalbondswithsurfacestopreventcorrosionandrust.
INTRODUCTION
This workshop is a publish sector industry which is governed by the works /workshop manager how is appointed by the central govt. He is responsible for every action in the workshop. There are many persons employed in the workshop for various works. The investment for the industry is done by the central govt.
Initially the workshop was concerned with the manufacturing and maintenance of stream engine. Now the stream engine outdated so the workshop has adopted a new line of action maintenance of railway wagons and steam engines some part used in diesel locomotives are also manufactured here such as blocks, rear cover, front covers, nuts face plates etc.
This workshop is divided into a number of shops. Each shop does a specific job all the shop is separately managed by senior section engineer with the help of junior engineer in the various sections of the shop. A large number workshop work here on a large number of machines.
The officers time to time inspect the workshop order to examine the quality of raw materials and products manufacture. There is also a chemical and metallurgical testing lab where researches on samples of raw materials and products are done and reports are issued whether the thing is ok or not.
THE STOP DEALS WITH TOOL OWING SECTION:-
A. Turbo machining section
B. Cylinder head & blast section
C. Fuel pump support cam shaft at section
D. Cylinder head assembly section
E. Turbo as cylinder
F. Governor drive, water pump, fan drive, L.O,pump. After cooler assembly .Section point 3-6 is a sub assembly section.
CYLINDER HEADSECTION:-
The layout of this section products type. There are different machine bed down setup per sequence of operation of cylinder head.
Shot blasting:-
This section related 05 shop connected cylinder head section. Size to shot is 0.028”. Material used for shot.
(a) Silicon oxide (Si O2)
(b) Aluminiumtri oxide(Al2 O3) mostly used.
BRACKING SYSTEM
Brakes haves utmost importance in a moving body. Every moving body has brakes to control the speed or motion. Various mechanisms are employed for braking system. Frictional forces is utilized in process of application of brakes. Therefore, our braking system issues maximum development of frictional forces. In the Indian railway, there are used two type 0f braking system in the engines and all types of coaches.
The two type of braking systems are-
1. Vacuum brake system
2. Air brake system
Vacuum brake system
Vacuum brake system has so for being considered standard on Indian railways, but now it is gradually replaced by air brakes. It is now considered for coaching stocks except in BG electrical multiple unit and BG/ MG diesel rail cars.
The main part of vacuum brake system are-
1. Direct admission valve
2. Hose pipe
3. Vacuum reservoir
4. Slack adjuster
5. Brake cylinder
PASSENGER EMERGENCY ALARM SIGNAL DEVICE
It is fitting on the coach and it is connected to alarm chain for actuating passenger emergency valve.
The main parts of air brakes system are following-
1. Brake cylinder
2. Brake pipe
3. Feed pipe
4. Distributor pipe
5. Angle cock
6. Hose pipe
7. Auxiliary reservoir
8. Guard’s van valve and pressure gauge
9. Isolating cock
10. Passenger emergency alarm single device
11. Passenger emergency alarm valve
12. Dirt collector
PLANT LAYOUT
Plant Layout is the physical arrangement of equipment and facilities within a Plant. The Plant Layout can be indicated on a floor plan showing the distances between different features of the plant. Optimizing the Layout of a Plant can improve productivity, safety and quality of Products. Unnecessary efforts of materials handling can be avoided.
Following points are considered while preparing the plant layout:-
1) Economic consideration- construction & operation cost.
2) Process requirement
3) Convenience of operation
4) Convenience of maintenance
5) Safety
6) Future expansion
7) Modular construction
DIVERSIFICATION/ENHANCEMEN SCOPE
The mechanical workshop N.E.R. railway GKP is a public sector industry which is governed by the work/workshop manager who is appointed by the central govt. And it is very large rang is very cover whole NER railway zone form GKP, Assam. This N. E. R. workshop also covers the area West Bengal.
The NER mechanical workshop GKP is well established and decorated with modern machines which are used to repair and manufacture all the parts and components of railway path, rail engine and compartment.
Repairing of all type of brake like air brake and feed brake.
3- Dimensional solid moulding
Product design and mould validation of Injection Moulding
Compression Moulding and Transfer Moulding process
Process simulation and mould design validation of Blow moulding
3-D & 2-D Digitising
Wiring and fitting of bulb, fan and. in apartment of trains .
CONCLUSION
The development and growth of locomotive workshop D.L.W.Varanasi processing industry is dependent upon the availability of skilled and technically trained. With a rapid development in the field of railway workshop processing using modern machine, there has been increased demand of manpower for designing, tool making, and railway workshop quality assurance to meet the diverse requirement of industries.
Hence, the manpower demand will also increase as the metallic material consumption increases in the coming years. Since, D.L.W locomotive workshop is the only workshop of its Bengal and Assam North west Railway loco and carriage workshop. Skilled workshop, were brought from Varanasi (U.P).
D.L.W workshop services would be more congruous for the railway reaping and allied industries in the years to come in terms of specialized training man power support technology support, quality and productivity improvement, developmental activities to newer technologies etc.