RPORT ON S\MMR TRAINING

AT IW, VARANASI
By: HImunsLu SIngL
MI ?
tL
semestev
vonucLuvuyu co!!ege oI engg.
IIA !AI!WAYS: AT A C!ACI
IndIun RuI!wuys (HIndI: Blro/|,o
Ioil), nbbrovInfod ns IR (HIndI: ), Is
n donrfmonfnI undorfnkIng of Covornmonf of IndIn,
whIch owns nnd oornfos mosf of IndIn's rnII
frnnsorf If Is ovorsoon by fho MInIsfry of
!nIIwnys of fho Covornmonf of IndIn
IndInn !nIIwnys hns ll3,6l? kIIomofros (?0,598 mI)
of fofnI frnck ovor n roufo of 63,9?4 kIIomofros (39,?52
mI) nnd ?,083 sfnfIons If hns fho worId's fourfh
Inrgosf rnIIwny nofwork nffor fhoso of fho !SA ,
!ussIn nnd ChInn Tho rnIIwnys frnvorso fho Iongfh
nnd brondfh of fho counfry nnd cnrry ovor 30 mIIIIon
nssongors nnd 28 mIIIIon fons of froIghf dnIIy If Is
fho worId's socond Inrgosf commorcInI or ufIIIfy
omIoyor, wIfh moro fhnn l36 mIIIIon omIoyoos As
for roIIIng sfock, I! owns ovor 2l9,93l (froIghf)
wngons, 5l,030 conchos nnd 8,889 IocomofIvos
!!O!CTIO !ITS
IndInn !nIIwnys mnnufncfuros much of Ifs roIIIng
sfock nnd honvy ongInoorIng comononfs nf Ifs sIx
mnnufncfurIng Innfs, cnIIod !roducfIon !nIfs, whIch
nro mnnngod dIrocfIy by fho MInIsfry !ouInr roIIIng
sfock buIIdors such ns C!W nnd !W for oIocfrIc nnd
dIosoI IocomofIvos; ICI nnd !CI for nssongor
conchos nro !roducfIon !nIfs of IndInn !nIIwnys
Ovor fho yonrs, IndInn !nIIwnys hns nof onIy
nchIovod soIf-suffIcIoncy In roducfIon of roIIIng sfock
In fho counfry buf nIso oxorfod roIIIng sfock fo ofhor
counfrIos Inch of fhoso sIx roducfIon unIfs Is
hondod by n ConornI Mnnngor, who nIso roorfs
dIrocfIy fo fho !nIIwny Ionrd Tho sIx !roducfIon
!nIfs nro:-
S!. No Nume Abbv.
Yeuv
stub!IsLed
IocutIon
MuIn
pvoducts
l
ChIffnrnnjnn
!ocomofIvo
Works
C!W l94? ChIffnrnnjnn
IIocfrIc
!ocomofIvos
2
IosoI
!ocomofIvo
Works
!W l96l VnrnnnsI
IosoI-oIocfrIc
!ocomofIvos
3
IosoI-!oco
ModornIsnfIon
Works
!W l98l !nfInIn
IosoI-oIocfrIc
!ocomofIvos
4
InfogrnI Conch
Incfory
ICI l952 ChonnnI
!nssongor
conchos
5
InfogrnI Conch
Incfory
!CI l986 KnurfhnIn
!nssongor
conchos
6
!nII WhooI
Incfory
!WI l984 InngnIoro
!nIIwny
whooIs nnd
nxIos
IISI! !OCOMOTIVI WO!KS, VA!AASI
IrIof hIsfory
August 1361 DLW set up as a green field project in
technical collaboration with ALCO,
USA for manufacture of Diesel
Electric Locomotives
]anuary 1364
First Locomotive rolled out and dedicated
to the Nation
]anuary 1376
Entered Export market, first locomotive
exported to Tanzania
December 1377 First Diesel Cenerating Set commissioned
October 133S The Transfer of Technology agreement
was signed
Narch 2002
The first indigenous END WDC4 freight
loco manufactured
November 2002 3600 HP Engine produced
Narch
2003
The first indigenous passenger version of
END loco WDP4 manufactured
September 2003
Development of 16 cylinder 3300 HP
Power upgraded DLW engine,
WDN3D locomotive
2006 S000
th
locomotive produced
November 2006
DLW manufactured first WDC4 locomotive
equipped with !CBT based converter
Narch 2007
First WDP4 locomotive equipped with !CBT
based converter
April 2007
DLW has successfully switched over to use
of microprocessor based control system on
all its locomotives.
Narch 2003
2S7 locomotives manufactured in 200803,
highest ever locomotive production
November 2003
S630 locomotives upto
30
th
Nov'2003(including 348 END locos)
O!CAIZATIOA! ST!ICTH
A fIngshI roducfIon unIf of IndInn !nIIwnys offorIng
comIofo rnngo of roducfs In Ifs nron of oornfIon
wIfh nnnunI furnovor of ovor 2l24 Croro
Sfnfo of fho nrf osIgn nnd MnnufncfurIng fncIIIfy fo
mnnufncfuro 200 IocomofIvos or nnnum wIfh wIdo
rnngo of roInfod roducfs vIz C Sofs, !oco
comononfs nnd sub-nssombIIos
SuIy of snros roquIrod fo mnInfnIn IosoI
!ocomofIvos nnd C sofs
!nbonfnbIo frnII-bInzIng frnck rocord In rovIdIng
cosf-offocfIvo, oco-frIondIy nnd roIInbIo soIufIons fo
ovor IncronsIng frnnsorfnfIon noods for ovor four
docndos
IuIIy gonrod fo moof socIfIc frnnsorfnfIon noods by
uffIng !rIco - VnIuo - TochnoIogy oqunfIon orfocfIy
rIghf
A Inrgo bnso of doIIghfod cusfomors nmong mnny
counfrIos vIz Mynnmnr, SrI !nnkn, MnInysIn,
VIofnnm, InngIndosh, TnnznnIn, AngoIn, fo nnmo n
fow, bonrIng fosfImony fo roducf IondorshI In Ifs
cnfogory
TY!IS OI !OCOMOTIVIS !!O!CI AT
!W
TLe IIvst !ettev (guuge)
l W-IndInn brond gnugo (Tho "W" Sfnnds for WIdo Cnugo -
5 Ioof)
2 Y-mofro gnugo (Tho "Y" sfnnds for Ynrd Cnugo - 3 Ioof)
3 Z-nnrrow gnugo(2 ff 6 In)
4 -nnrrow gnugo (2 ff)
TLe second !ettev (motIve powev)
l -IosoI
2 C-C oIocfrIc (cnn run undor C frncfIon onIy)
3 A-AC oIocfrIc (cnn run undor AC frncfIon onIy)
4 CA-Iofh C nnd AC (cnn run undor bofh AC nnd C
frncfIons), 'CA' Is consIdorod n sIngIo Ioffor
5 I-Inffory oIocfrIc IocomofIvo (rnro)
TLe tLIvd !ettev (Job type)
l C-goods
2 !-nssongor
3 M-mIxod; bofh goods nnd nssongor
4 S-!sod for shunfIng (AIso known ns swIfchIng
ongInos or swIfchors In !nIfod sfnfos nnd somo
ofhor counfrIos)
5 !-IIocfrIc muIfIIo unIfs (usod ns commufors In cIfy
suburbs)
6 !-!nIIcnrs
Ior oxnmIo, In "WM 3A":
l "W" monns brond gnugo
2 "" monns dIosoI mofIvo owor
3 "M" monns suIfnbIo for mIxod(for bofh goods
nnd nssongor)sorvIco
4 "3A" monns fho IocomofIvo's owor Is 3,l00 h ('3'
sfnnds for 3000 h, 'A' donofos l00 h moro)
Or, In "WAP 5":
l "W" monns brond gnugo
2 "A" monn AC oIocfrIc frncfIon mofIvo owor
3 "!" monns suIfnbIo for !nssongor sorvIco
4 "5" donofos fhnf fhIs IocomofIvo
Is cLvono!ogIcu!!y fho fIffh oIocfrIc IocomofIvo
modoI usod by fho rnIIwnys for nssongor sorvIco
ISI TRACTION
ASSMBIY AT IW
IoIIowIng fyos of dIosoI Ioco nro boIng roducod
In fho !W:
l WM - WIdo IosoI MIxod
2 W! - WIdo IosoI !nssongor
3 WC - WIdo IosoI Coods
4 WS - WIdo IosoI Shunfor
WM CIASS
S!ICIIICATIO OI WM C!ASS
Powev type Iese!
IuIIdor AIco, !W
ModoI !560C
IuIId dnfo l962 onwnrds
TofnI roducfIon 2?00+
!IC cInssIfIcnfIon Co-Co
Cnugo l,6?6 mm (5 ff 6 In)
WhooI dInmofor l,092 mm (3 ff ?0 In)
WhooIbnso l2834 m (42 ff l3 In)
!ongfh l?l2 m (56 ff 2 In)
WIdfh 2864 m (9 ff 48 In)
HoIghf 4l85 m (l3 ff 88 In)
AxIo Iond l8,800 kg (4l,000 Ib)
IocomotIve weIgLt 112,B00 kg (249,000 !b)
IuoI cnncIfy 5,000 I (l,l00 Im gnI; l,300 !S
gnI)
!rImo movor A!CO 25l-I
IngIno !!M rnngo 400 - l000 rm
AsIrnfIon Turbo-suorchnrgod
CyIIndors l6
To sood l20 km/h (?5 mh)
!owor oufuf 2,400 h (l,800 kW)
Incfor of ndhosIon 02?
IsosIfIon ncfIvo
!I!IO!MACI
Tho cInss WM-2 Is IndInn !nIIwnys'
workhorso dIosoI IocomofIvo Tho fIrsf unIfs woro
Imorfod fuIIy buIIf from fho AmorIcnn !ocomofIvo
Comnny (AIco) In l962 SInco l964, If hns boon
mnnufncfurod In IndIn by fho IosoI !ocomofIvo
Works (!W), VnrnnnsI Tho modoI nnmo sfnnds
for brond gnugo (W), dIosoI (), mIxod frnffIc (M)
ongIno Tho WM-2 Is fho mosf common dIosoI
IocomofIvo of IndInn !nIIwnys
Tho WM-2A Is n vnrInnf of fho orIgInnI WM-2
Thoso unIfs hnvo boon rofro-fIffod wIfh nIr brnkos, In
nddIfIon fo fho orIgInnI vncuum brnkos ThoWM-
2B Is n moro roconf IocomofIvo, buIIf wIfh nIr brnkos
ns orIgInnI oquImonf Tho WM-2 Iocos hnvo n
mnxImum sood of l20 km/h (?5 mh) , rosfrIcfod fo
l00 km/h (62 mh) whon run Iong hood forwnrd - fho
gonr rnfIo Is 65:l8
WG CIASS
S!ICIIICATIO OI WC C!ASS
Powev type Iese!-e!ectvIc
IuIIdor IM & !W
ModoI CT46!AC
IuIId dnfo (IM) 200l; (!W) 2003
!rosonf
TofnI roducfIon (IM) l0; (!W) 80+ undor
IIconso (In roducfIon)
AA! whooI nrr AlA-AlA
Cnugo 5 ff 6 In (l68 m)
Trucks HTSC
IogIos
W
Io-l-l-Io (W!-4)
W
Co-Co (W!-4I nnd W!-4)
IuoI fyo dIosoI
ue! cupucIty 6,000 !Itevs
!rImo movor l6-?l0C3I
IngIno fyo 2-sfroko dIosoI
AsIrnfIon furbochnrgod
IsIncomonf ll,360 In (l862 IIfors)
AIfornnfor TA-l?-CA6A
TrncfIon mofors AC
CyIIndors Vl6
TrnnsmIssIon oIocfrIc; AC nIfornnfor, l Invorfor
or fruck, AC frncfIon mofors
!owor oufuf
W
4,000 h (W!-4)
W
4500 h (W!-4I nnd W!-4)
!ocomofIvo brnkos nIr
TrnIn brnkos nIr
!I!IO!MACI
Tho W!-4 Is cnnbIo of hnuIIng 24 conch frnIns nf ll0-l20
km/hour If hns nIso boon usod for sood frInIs whoro If hns
hnuIod 8 conch frnIns nf l60 km/hour
Tho IocomofIvos cnn bo usod In oIfhor dIrocfIon, nnd
froquonfIy hnuI frnIns Iong hood forwnrd, ns In fho Icfuro
owor odIfIons wIfh 4500h hnvo boon roducod whIch
hnvo boon nnmod wIfh fho sub cInss W!-4I /W!-4
whIch hnvo dIfforonf frncfIon confroI wIfh sIx frncfIon
mofors nnd nro Co-Co bogIo oquIod, unIIko fho orIgInnI
whIch hns n Io-l-l-Io nrrnngomonf wIfh four frncfIon
mofors
Tho Ioco Is vory fuoI offIcIonf nnd hns mInImnI oxhnusf
omIssIons duo fo Ifs 2 sfroko dIosoI ongIno If Is
chnrncforIzod by Ifs Ioud horn, whIch cnn bo honrd for Inrgo
dIsfnncos nround, nnd nIrcrnff-IIko sound of Ifs runnIng
ongIno
T!AIIC !I!IO
IoIIowIng four worksho woro nssIgnod fo mo
durIng my frnInIng orIod of four wooks:
l Honvy WoIdIng Sho
2 Honvy MnchIno Sho
3 Truck MnchIno Sho
4 Honf Tronfmonf Sho
HIAVY WI!IC SHO!
In honvy woIdIng sho sfooI shoofs of nbouf ?5mm nro
woIdod fogofhor To form ongIno bIock for bofh A!CO
nnd CM ongInos Tho convonfIonnI form of
mnnufncfurIng ongIno bIocks of such onormous sIzo
wouId hnvo boon vory unoconomIcnI
Tho fhroo mnIn fyo of woIdIng nro:
l Submorgod Arc WoIdIng (SAW)
2 ShIoIdod MofnI Arc WoIdIng (SMAW)
3 Cns MofnI Arc WoIdIng (CMAW)
Affor woIdIng fho ongIno bIocks nro fhoroughIy
Insocfod for undor woIdIng nnd ovor woIdIng
InfornnI crncks nro dofocfod usIng T
Tho bIocks nro fhon nssod fo HMS for furfhor
mnchInIng nnd borIng of hoIos for cyIIndors or
!owor !nck AssombIy ConornIIy l2 fo l6 hoIos
nro borod
HIAVY MACHII SHO!
As fho nnmo suggosfs In fho honvy mnchIno sho
fho fInIshod ongIno bIocks nro fhon mnchInod
uon fo roduco hoIos for owor nck nssombIy
Tho mnIn mnchInos In HMS nro:
l AnguInr borIng mnchIno (TA! / HMT)
2 CC !orfnI mIIIIng ( WnIdrIch coburg)
3 !ndInI rIII (mnx 25 fon)
4 HydrnuIIc ross
HIAT T!IATMIT SHO!
AII fho comononfs usod In nn ongIno nro honf fronfod
boforo fhoy nro nssombIod Tho mnIn objocfIvo bohInd
honf fronfmonf Is fo Imrovo fho mnchInnbIIIfy nnd
wonr rosIsfnnco of fho comononfs
Somo of fho honf fronfmonf usod nro :
l ormnIIzIng
2 "uonchIng
3 CnrburIzIng
4 InducfIon hnrdonIng
N
O
R
M
A
L
1
Z
1
N
C
In fho fIguro n
normnIIzIng
furnnco Is shown
IMAL1Z1

"
\

N
C
H
I
N
G
In fho fIguro
quonchIng fnnk Is
usod
"&1
In quonchIng fho mnforInI Is honfod fo n
fomornfuro of nbouf 8l5 fo 900C nnd fhon If Is
rnIdIy cooIod by n mIxfuro of wnfor nnd
oIysfyrono gIycoI
Tho mnIn ndvnnfngo of quonchIng Is fo Imrovo
mnchInnbIIIfy, hnrdnoss nnd dovoIomonf of
mnrfonsIfo sfrucfuro ConornIIy nII fho
comononfs usod In fho IocomofIvo nro quonchod
boforo nny ofhor honf fronfmonf rocoss
C
A
R
B
\
R
I
Z
I
N
G
In fho fIguro n
cnrburIzIng
furnnco Is shown
AIB&I1Z1 I AS AID1
In fhIs rocoss n hnrd surfnco Is roducod on n
Iow cnrbon sfooI of 0l5 orconf cnrbon In courso
of rocoss fho oufor Inyor Is convorfod Info n hIgh
cnrbon sfooI wIfh n cnrbon confonf rnngIng from
09 fo l2 or conf of n cnrbon
Tho comononfs In fho cnrburIzIng rocoss nro
kof In confncf wIfh cnrbonncoous comounds
nnd onorgIzor (InCO3) Thon fhoy nro kof
fogofhor In n furnnco for n gIvon orIod of fImo
Tho hnrdnoss doonds uon fho onofrnfIon of
cnrbon, fomornfuro nnd fImo u fo whIch Ifs Is
kof In furnnco An hour of honfIng roducos
4000 fo 5000 hnrdnoss
Tho mnIn comononfs whIch nro cnrburIzod In
fho HTS nro mnIn Isfon In, rockor nrm
nssombIy, crnb boIfs ofc
1D&%1 AID1
InducfIon hnrdonIng rocoss Is fho honf fronfmonf
rocoss In whIch comononfs of hIgh cnrbon
orconfngo nro hnrdonod usIng hIgh froquoncy nc
curronf ConornIIy n d of 200kv fo l30kv Is usod
In InducfIon hnrdonIng rocoss fhoro Is no chnngo In
chomIcnI comosIfIon Tho work Ioco Is kof nf n
dIsfnnco of 3-4 mm from fho coIIs Tho curronf
roducos n mngnofIc fIux whIch roducos oddy
curronf rosuIfIng In honfIng
IH Is gonornIIy dono on crnnkshnffs who hnvo n hIgh
orconfngo of cnrbon sny nbouf 45 fo 48 orconf
S!CCISTIOS
Tho worksho Is nof usor frIondIy
CongosfIon nnd Inck of snco
Snfofy nnd SocurIfy