dlw varanasi

Diesel Locomotive Works

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 nation. DLW catch the attention of lot of foreign tourist students to observer on going amazing locomotive manufacturing process in Varanasi. Diesel Locomotive works Varanasi is located at the North end of the city and about 8 Km away from the Holy River Ganges Ghats. DLW is an ISO 9002, ISO 14001 & OHS 18001 Certified Organization of diesel electric locomotive.

Diesel Locomotive Works, Varanasi (DLW) is one of the main manufacturing units run by the Indian Railways. This manufacturing unit came into existence in year 1961, as a “Green Field Project” in industrial association with ALCO, USA. This unit generate all the Diesel Electric Locomotives. In year 1964, 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.

Diesel Locomotive manufacturing Works, Varanasi is works into three main sections that include

Engine section Vehicle section Block section

Engine section manufacture more than 2000 machinery, which comprise ALCO turbo superchargers, cylinder heads, connecting rods, camshafts, lubricating oil pumps, chrome plated cylinder liners and many different types of gears

Vehicle section of DLW unit works on different fields that include Bogie Manufacturing, Component Fabrication, Locomotive Assembly, under frame Fabrication, and many more.

Currently, Diesel Locomotive Works, Varanasi constructs locomotives and DG sets. In locomotives section, again it manufactures two different types of products, one is EMD and another is ALCO.

Classification of Locomotives

In India, locomotives are classified according to their track gauge, motive power, the work they are suited for and their power or model number. The class name includes this information about the locomotive. It comprises 4 or 5 letters. The first letter denotes the track gauge. The second letter denotes their motive power (Diesel or Electric) and the third letter denotes the kind of traffic for which they are suited (goods, passenger, mixed or shunting).One of the earliest pictures of railways in India

The fourth letter used to denote locomotives' chronological model number. However, from 2002 a new classification scheme has been adopted. Under this system, for newer diesel locomotives, the fourth letter will denote their horsepower range. Electric locomotives don't come under this scheme and even all diesel locos are not covered. For them this letter denotes their model number as usual.

A locomotive may sometimes have a fifth letter in its name which generally denotes a technical variant or subclass or subtype. This fifth letter indicates some smaller variation in the basic model or series, perhaps different motors, or a different manufacturer. With the new scheme for classifying diesel locomotives (as mentioned above) the fifth item is a letter that further refines the horsepower indication in 100 hp increments: 'A' for 100 hp, 'B' for 200 hp, 'C' for 300 hp, etc. So in this scheme, a WDM-3A refers to a 3100 hp loco, while a WDM-3F would be a 3600 hp loco.

The classification syntaxes

The first letter (gauge)

W-Indian broad gauge (The "W" Stands for Wide Gauge - 5 Feet 6 inches) Y-metre gauge (The "Y" stands for Yard Gauge - 3 Feet or 1000mm) Z-narrow gauge(2 ft 6 in) N-narrow gauge (2 ft)

The second letter (motive power)

D-Diesel

C-DC electric (can run under DC traction only) A-AC electric (can run under AC traction only) CA-Both DC and AC (can run under both AC and DC tractions), 'CA' is considered a

single letter B-Battery electric locomotive (rare)

The third letter (job type)

G-goods P-passenger M-mixed; both goods and passenger S-Used for shunting (Also known as switching engines or switchers in United states and

some other countries) U-Electric multiple units (used as commuters in city suburbs) R-Railcars

For example, in "WDM 3A":

"W" means broad gauge "D" means diesel motive power "M" means suitable for mixed(for both goods and passenger)service "3A" means the locomotive's power is 3,100 hp ('3' stands for 3000 hp, 'A' denotes 100

hp more)

Or, in "WAP 5":

"W" means broad gauge "A" mean AC electric traction motive power "P" means suitable for Passenger service "5" denotes that this locomotive is chronologically the fifth electric locomotive model

used by the railways for passenger service.

Different Types of locos-

Diesel traction

WDM - Wide Diesel Mixed WDP - Wide Diesel Passenger WDG - Wide Diesel Goods WDS - Wide Diesel Shunter

Mixed type locomotives:

WDM 1 (First mainline diesel electric locomotives used in India. Introduced in 1957. Imported from ALCO. Out of service now. 1950 hp)

WDM 2 (Most widely used and first homemade mainline diesel-electric locomotives in India. Original prototypes were made by ALCO. Introduced in 1962. More than 2700 have been made. Rated at 2600 hp)

WDM 2A,WDM 2B (Technical variants of WDM 2) WDM 3 (Only 8 were imported. They used hydraulic transmission and are currently non-

functional) WDM 3A (Formerly WDM 2C. Another WDM 2 variant. It is not related to WDM 3.

3100 hp) WDM 3A R (Formerly WDM 2. It is a rebuilt with DBR fitted on Short Hood. It is not

related to WDM 3. 3100 hp) WDM 3C, WDM 3D (higher powered versions of WDM 3A) WDM 4 (Entered service along with WDM 2. Prototypes designed by General Motors.

Though considered superior to WDM 2 in many ways, these locomotives weren't chosen as General Motors did not agree to a technology transfer agreement. 2600 hp)

WDM 6 (Very rare class; only two were made; one is being used by Puttalam Cement Factory in Sri Lanka. Rated at 1200 HP)

WDM 7 (Fifteen of these locos were built from June 1987 through 1989, they were designed for branch-line duties, but they are now used mostly for shunting. Rated at 2000 hp)

Passenger locomotives:

WDP 1 WDP 2 (New class name WDP 3A. Dedicated passenger diesel locomotive. Entered

service in 1998. Powerful locomotive. 3100 hp) WDP 3 (This locomotives are actually prototypes of the class WDP 1 and never entered

serial production.) WDP 4 (EMD (former GM-EMD) GT46PAC, fundamentally a passenger version of the

WDG 4 (GT46MAC). 4000 hp) WDP 4B (EMD (former GM-EMD) GT46PAC, An improved version of the WDP 4, this

is a more powerful version and has 6 traction motors, just like the WDG 4. Also comes with wider cabin to aid visibility and minor exterior design changes. 4500 hp)

WDP 4D (EMD (former GM-EMD) GT46PAC, This is basically a WDP 4B with twin cabs. Minor changes were made to the locomotive to facilitate the addition of a second cabin. This locomotive comes with LCD instrument display and toilet for the drivers. As of now, two units have been made and are expected to enter full-time service soon. 4500 hp)

Goods locomotives:

DG 2 (New class name WDG 3A. These class is actually a technically upgraded form of WDM 2)

WDG 3B, WDG 3C, WDG 3D (Technical upgraded forms of WDG 2 or WDG 3A) WDG 4 (New dedicated goods locomotives. These are General motors' GT46MAC

models. First units were imported in 1999. They are numbered from #12000 upward. Local production started on 2002. 4000 hp)

WDG 5 (Another Freight dedicated Locomotive developed by Diesel Locomotive Works and Supported by Electro Motive Diesels. First unit was rolled out from DLW on 25 February 2012. They are numbered from #50001 upward. Rated at 5500 hp. Equipped with Fire Control System, TFT Display and Driver's Toilet.)Loco is still under trials in DLW, Varanasi. The locomotive/series is named 'BHEEM', after the strong Pandav brother from epic of Mahabharat.

Shunting locomotives (Also known as switching engines):

WDS 1 (First widely deployed and successful diesel locomotives used in India. Imported in 1944-45. currently out of service. 386 hp)

WDS 2 (currently out of service.) WDS 3 (All locomotives of this class were rebuilt and reclassified as WDS 4C in 1976-

78. 618 hp) WDS 4,WDS 4A,WDS 4B,WDS 4D (Designed by Chittaranjan Locomotive Works.

600-700 hp) WDS 4C (Rebuilt WDS 3 locos as mentioned above) WDS 5 (Some of these locomotives are used for industrial shunting. A few are used on

Indian Railways. Rated at 1065 hp) WDS 6 (Heavy-haul shunters made in large numbers for industrial concerns as well as

for Indian Railways Rated at 1200/1350 hp) WDS 8 (Only five of these were made, and all were transferred to steel works 800 hp)

Products manufactured at DLW Varanasi-

DLW manufactures two different types of products

EMD ALCO

EMD WDG4 - 4000 HP GOODS LOCOMOTIVE

Broad Gauge freight traffic Co-Co diesel electric locomotive with 16

Cylinder 4000 HP engine, AC-AC transmission, microprocessor controlled propulsion and braking with high traction high speed cast steel trucks.

First turned out in 1999 with transfer of technology from General Motor (USA), this locomotive has exceptional fuel efficiency and very low maintenance requirements. It is specifically designed for heavy haul freight traffic requirements of Indian Railways for the 21st Century.

The heart of loco Traction Control Converter uses the GTO devices (obsolete technology). Now the IGBT devices, has been introduced from Oct�2006. It is the latest technology and will be cost effective and gives higher reliability.

The locomotive power has been upgraded to 4500 BCV and the first Loco (Loco No 12114) was manufactured in May�07

Diesel EngineTransmission

16 Cylinder 710 G3B, 2 stroke, turbocharged � after cooled

Fuel Efficient Engine

Injection System � Direct Unit Injector

Governor � Woodward

Compression Ratio- 16:1

Lube Oil Sump Capacity � 950 Lts

Electrical AC-AC

6 Traction motor ( 3 in parallel per bogie)

Suspension � Axle hung / taper roller bearing

Gear Ratio � 90:17

Truck Brakes

High adhesion HTSC ( High Tensile Steel Cast) truck of bogie

Adhesion � 0.42

Electronic Air Brake System ( KNORR-NYAB-Computer Controlled Braking)

Air , hand , dynamic brake

Pure air brake

General Characteristic

Installed Power

Axle Load

4000 HP

21 T

Gauge

Wheel arrangement

Wheel diameter

Height

Width

Overall Length (Over

Buffer Beam)

Weight

Max tractive effort

Maximum speed

Fuel tank capacity

Locomotive Control

1676 mm

Co-Co

1092 mm

4201 mm

3127 mm

19964 mm

126 T

54 T

100 Kmph

6000 lts

EM 2000 with SIBAS-16

Traction Control

WDG4-4000 HP GOODS LOCOMOTIVE

TRACTIVE EFFORT & POWER CHART

WDP4 � 4000 HP PASSENGER LOCOMOTIVE

State-of-Art, Microprocessor controlled AC-AC, Passenger Locomotive Powered with 16-710G3B 4000HP Turbo charged Two stroke Engine.

Fabricated rigid design Under frame, two stage suspension, High Traction High Speed 3 axle (HTSC) light weight cast truck frame attribute to high

adhesion performance.

First turned out in 2003, 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 4500 HP. The prototype will be manufactured in the year 2007.

Diesel EngineTransmission

16 Cylinder 710 G3B, 2 stroke, turbocharged � after cooled

Fuel Efficient Engine

Injection System � Direct Unit Injector

Governor � Woodward

Compression Ratio- 16:1

Lube Oil Sump Capacity � 1073 Lts

Electrical AC-AC

4 Traction motor ( 3 in parallel per bogie)

Suspension � Axle hung / taper roller bearing

Gear Ratio � 77:17

Truck Brakes

High adhesion HTSC ( High Tensile Steel Cast) truck or bogie

Adhesion � 0.42

Electronic Air Brake System ( KNORR-NYAB-Computer Controlled Braking)

Air , hand , dynamic brake with fully blended with automatic brakes

Pure air brake

General Characteristic

Installed Power

Axle Load

Gauge

Wheel arrangement

4000 HP

19.5 T

1676 mm

A-A-I I-A-A

Wheel diameter

Height

Width

Overall Length (Over

Buffer Beam)

Weight

Max tractive effort

Maximum speed

Fuel tank capacity

Locomotive Control

1092 mm

4201mm

3127 mm

19964 mm

117 T

27 T

160 Kmph

4000 lts

EM 2000 with SIBAS-16

Traction Control

ALCO

1350 HP CAPE GAUGE LOCOMOTIVEVDM 4

TECHNICAL INFORMATION1350 HP Locomotive having fabricated cape gauge Co-Co bogie. hese locomotives have been supplied to Angola and Sudan. Wheel Arrangement Co - Co

Track Gauge 1067 mm Cape gauge

Weight 72 t

Overall Length 15600 mm

Wheel Diameter 921 mm

Gear Ratio 18: 93

Maximum Speed 90 Kmph

Diesel Engine Type : ALCO 251 D 6 Cyl. in line.

HP 1350

Transmission Electrical AC/DC

Brake 28LAV-1 system

Loco Air, dynamic, parking

Train Air & Vacuum

Fuel Tank Capacity 3000 Litres

Contact Details for Product Purchase

2300 HP CAPE GAUGE LOCOMOTIVE

TECHNICAL INFORMATION2300 HP Main Line Locomotive, having fabricated cape gauge Co-Co bogies. These are provided with two drivers cabs, one at each end. These locomotives have been supplied to Angola and Sudan.Wheel Arrangement Co-Co

Track Gauge 1067 mm Cape Gauge

Weight 102 t



Gear Ratio 18 : 93


Diesel Engine Type : ALCO 251-B 12 Cyl. V- Engine

HP 2300


Brake IRAB-1

Loco Air, Dynamic, parking

Train Air



2300 HP METER GAUGE LOCOMOTIVE

TECHNICAL INFORMATION2300 HP Main Line Locomotive, having fabricated meter gauge Co-Co bogies. These are provided with two drivers cabs, one at each end. These locos have been supplied to Malaysia, Senegal and Mali. Wheel Arrangement Co-Co

Track Gauge 1000 mm Meter Gauge

Weight 102 t



Gear Ratio 18 : 93


Diesel Engine Type : ALCO 251-B 12 Cyl. V- Engine

HP 2300


Brake IRAB-1

Loco Air, Dynamic, parking

Train Air



3000 HP CAPE GAUGE LOCOMOTIVE

TECHNICAL INFORMATION( Provisional Specifications)3000 HP Micro Processor Controlled, Main Line, Cape Gauge Locomotive with improved Cab, under development for Mozambique Railway.

Wheel Arrangement Co-Co

Track Gauge 1067 mm Cape Gauge

Weight 114 t



Gear Ratio 19 : 92


Diesel Engine Type : ALCO 251-C 16 Cyl. V- Engine

HP 3000


Brake IRAB-1

Loco Air, Dynamic

Train Air



1350 HP METER GAUGE LOCOMOTIVE YDM4

TECHNICAL INFORMATION1350 HP Locomotive having cast / fabricated meter Gauge Co-Co bogie. Such locomotives have been supplied to Vietnam and Myanmar.Wheel Arrangement Co - Co

Track Gauge 1000 mm

Weight 72 t



Gear Ratio 18: 93


Diesel Engine ALCO 251 D 6 Cyl. in line.

HP 1350


Brake IRAB � 1 system / 28LAV-1

Loco Air, dynamic, parking

Train Air / Dual (Air and Vacuum)



BROAD GAUGE MAIN LINE FREIGHT LOCOMOTIVEWDG 3A

TECHNICAL INFORMATIONDiesel Electric main line, heavy duty goods service locomotive, with 16 cylinder ALCO engine and AC/DC traction with micro processor controls.Wheel Arrangement Co-Co

Track Gauge 1676 mm

Weight 123 t

Length over Buffers 19132 mm


Gear Ratio 18 : 74

Min radius of Curvature 117 m


Diesel Engine Type : 251 B,16 Cyl.- V

HP 3100

Brake IRAB-1

Loco Air, Dynamic

Train Air

Fuel Tank Capacity 6000 litres


BROAD GAUGE MAIN LINE MIXED SERVICE LOCOMOTIVEWDM 3D

TECHNICAL INFORMATIONDiesel Electric Locomotive with micro processor control suitable for main line mixed Service train operation. Wheel Arrangement Co-Co

Track Gauge 1676 mm

Weight 117 t

Max. Axle Load 19.5 t

Length over Buffer 18650 mm


Gear Ratio 18 : 65


Diesel Engine Type : 251 B-16 Cyl. �V� type (uprated)

HP 3300 HP (standard UIC condition)

Transmission Electric AC / DC

Brake IRAB-1 system

Loco Air, Dynamic, Hand

Train Air


BROAD GAUGE SHUNTING LOCOMOTIVEWDS 6AD

TECHNICAL INFORMATIONA heavy duty shunting Diesel Electric Locomotive for main line and branch line train operation. This locomotive is very popular with Steel Plants and Port Trusts.

Wheel Arrangement Co-Co

Track Gauge 1676 mm

Weight 113 t

Length over Buffer 17370 mm


Gear Ratio 74 : 18


Diesel Engine Type : 251 D-6 Cyl. in-line

HP 1350 / 1120 HP (std.)

Transmission Electric AC / DC

Brake IRAB-1

Loco Air

Train Air


Dlw Have 3 divisions

BLOCK DIVISION ENGINE DIVISION LOCO DIVISION

BLOCK DIVISION

Flame Cutting of ComponentsSteel plates of sizes up to 80 mm thickness are ultrasonically tested before being precision cut by numerically controlled flame cutting machines, Plasma Cutting Machine. Components are straightened and machined prior to fitting & tacking onfixture designed specially for engine block fabrication to ensure close tolerance on engine block.

Fabrication of Engine Block/ CrankcaseComponents 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, X-rays, Visual etc. Down-hand welding is ensured using specially designed positioners. Fabrication of engine block is completed by submerged arc welding using semi-automatic welding machines.Special fixtures are used for making down-hand 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.

Portal Milling MachineEngine block machining is done on Portal Milling Machine which is a 5 axis CNC machine with SIEMENs 840-D state of art system control with dedicated tool management system. This machine performs milling, drilling, tapping and boring operations in single setting. The machine accuracy of 10enables adhering to the tolerance required on engine block.

Angular Boring MachineAngular boring "V" boring is done of special purpose machine which is a special purpose machine, which has two high precision angular boring bars on which different boring inserts are mounted. The cutting inserts on boring bars to achieve evenly distributed cutting load during boring operation. This contributes to accuracy while machining. Boring bars are mounted on high precision bearings which provide control on size during angular boring. The machine is capable of boring and drilling to different sizes.

ENGINE DIVISION

COMPONENT MACHININGOver 2000 components are manufactured in-house at DLW. These include ALCO turbo super chargers, lubricating oil pumps, cam shafts, cylinder heads, laser hardened cylinder liners, connecting rods and various gears. Our well-equipped Machine Shops have dedicated lines for operations like turning, milling, gear hobbing, drilling, grinding and planning etc. In addition, DLW is equipped with a variety ofspecial purpose machines and a large number of state-of-the-art CNC machines to ensure quality and precision. Associated manufacturing process like heat treatment and induction hardening are also carried out in-house. A new eco friendly laser hardening machine has been setup which is designed to laser harden the inner bore of engine cylinder liner and this feature advantages such as low running cost, state of the art controls to provide reliable and versatile laser power for ultimate quality requirements.

Engine Assembly & TestingPre-inspected engine block, crankshaft, cylinder liners, pistons, connecting rods, cylinder heads, exhaust manifold, turbo supercharger and all related piping are used in assembly of engine. Electrical machines like traction alternator,auxiliary generator and exiter are thereafter coupled on the engine. The complete power pack with electrics are tested on computerized Engine Test Bed to verify prescribed horsepower output. Vital parameters of engine health are checked to assure the quality of product. Only after the engine parameters are found perfect the power pack are cleared for application on locomotives.

LOCO DIVISION

Component Fabrication

Precision cutting and forming of sheet metalis 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's control stands are done in another work area.

Underframe FabricationUnder frames are fabricated with due care to ensure designed weld strength. Requisite camber to the under frame is provided during fabrication itself. Critical welds are tested radio-graphically. Welder training and their technical competenceare periodically reviewed. High Horse Power (HHP) 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.

BOGIE MANUFACTURINGSpecial purpose machines are utilized for machining cast and fabricated bogie frames. Axle and wheel disc machining is undertaken on sophisticated CNC machines. Inner diameter of wheel discs are matched with the outer diameter ofaxles 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.

LOCOMOTIVE ASSEMBLYTested engines are receive from Engine Division. Similarly under frames are received from Loco frame shop and assembled trucks from Truck machine shop. Superstructure compartments and contractor compartment are received from Respective manufacturing and assembly shops of Vehicle Division. Important alignments like crank shaft deflection, compressor alignment and Eddy Current clutch/radiator fan alignment are done during assembly stage. 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 spray painting. All locomotive are rigorous tested as per laid down test procedures before the locomotive is taken up for final painting and dispatch for service.

dlw varanasi

Documents

exceptional fuel efficiency

lubricating oil pumps

low maintenance requirements

special purpose machine

computer controlled braking

high adhesion htsc

means broad gauge

fabricated cape gauge