The presentation is related to my Internship at D.M.W, Patiala, one of the primate manufacturers for Indian Railways. The project assigned to me was to study the rehabilitation and remanufacturing of the Engine Block of a locomotive. Although there might be some minute loop holes in the presentation as it has been 2 years since I left that very place, but more or less everything is same. In fact, it was during my training that the Ministry of Railways decided to manufacture and roll out Multi- Genset loco called WDM 2G. So for any basic queries regarding the presentation feel free to contact.

1. PRESENTATION
ON
DIESEL LOCO- MODERNISATION WORKS, PATIALA
SUBMITTED BY:
ARJUN GAUR
DEPT. OF MECHANICAL ENGINEERING
90311125888/ 5914/ 2K9

2. INDIAN RAILWAYS AT A GLANCE
Indian state-owned enterprise, owned and operated by the government
of India through the Ministry of Railways.
115,000 km (71,000 mi) of track over a route of 65,000 km (40,000 mi) and
7,500 stations.
20 million passengers and 2.8 million tons of freight exchanged daily.
World's fourth largest commercial or utility employer, with over
1.4 million employees.
Operates in twenty four states and three union territories and
international services to Nepal, Bangladesh and Pakistan.
Divided into sixteen zones , and further sub-divided into divisions and
subdivisions.
1,676mm(5 ft. 6 in) Broad Gauge (BG), which is also called Indian gauge
used in plains.

3. SL. NO NAME ABBR.
YEAR
ESTABLISHED
LOCATION MAIN PRODUCTS
1.
GOLDEN ROCK LOCOMOTIVE
WORKSHOPS
GOC 1928 TRICHY Diesel-electric Locomotives
2.
CHITTARANJAN LOCOMOTIVE
WORKS
CLW 1947
CHITTARANJAN
, ASANSOL
Electric Locomotives
3. DIESEL LOCOMOTIVE WORKS DLW 1961 VARANASI Diesel Locomotives
4.
DIESEL-LOCO MODERNISATION
WORKS
DMW 1981 PATIALA Diesel-electric Locomotives
5. INTEGRAL COACH FACTORY ICF 1952 CHENNAI Passenger coaches
6. RAIL COACH FACTORY RCF 1986 KAPURTHALA Passenger coaches
7. RAIL WHEEL FACTORY RWF 1984 BANGALORE Railway wheels and axles
8. RAIL WHEEL FACTORY RWF 2011 CHHAPRA
Railway wheels and axles
PRODUCTION UNITS

4. ALCO-AMERICAN LOCOMOTIVE COMPANY
 INDUSTRY: RAIL TRANSPORT
 FOUNDED :1901
 HEADQUARTERS : NEW YORK
 PRODUCTS: STEAM and DIESEL-ELECTRIC LOCOMOTIVES.
 ARRIVAL IN INDIA : 1961 DLW
 MODEL SPECIFICATION : DL 535A, DL 560C.
 COMPETITOR : GM-EMD

5. THE DIESEL-ELECTRIC LOCO.
The fuel (diesel) is used to run the V-16 DIESEL ENGINE crankshaft which
in turns produces electric power through a machine called ALTERNATOR
(generator producing AC) and this power is transmitted to the axles after
passing through a series of conversions and components.

6. MAIN COMPONENTS OF THE LOCO.
DIESEL ENGINE (THE POWERPACK)
TRACTION ALTERNATOR
RECTIFIERS
CABIN (CONTROL STAND)
TRACTION MOTORS
FUEL TANK
AIR COMPRESSOR
RADIATORS AND FAN
BOGIES (MOTORISED WHEEL SETS WITH AXLES)
UNDERFRAME
SUPERSTRUCTURE (OUTER BODY)

7. NAMING A LOCOMOTIVE
WDM 3A
•W- wide or broad gauge (gauge type)
W-Wide Or Broad Gauge (Gauge Type)
D-Diesel Powered (Traction Type)
M-mixed Job Type (Passenger And Goods)
3-3000 Hp.
A-100 Hp, B-200 Hp, C-300 Hp and so on.
For electric locomotives “D” is replaced by “A” (for AC traction)

8. DIESEL LOCO-MODERNISATION WORKS ,PATIALA
Diesel loco-modernization works (formerly known as DIESEL COMPONENTS
WORKS [D.C.W]) is located in PATIALA city of PUNJAB .

9. Milestones…
Foundation stone of D.L.W VARANASI laid in the year 1961 in
collaboration with ALCO.
In 1979, decision to setup D.C.W PATIALA to meet the requirements
of the high precision diesel fleet was taken.
The Foundation Stone laid on October 24, 1981.
Production started in 1986 in phase-1.
Phase-2 of the project was sanctioned and the work of Rebuilding
started in 1989.
Name changed to Diesel Loco Modernization Works (DMW) in July,
2003 to signify the modernization of Diesel Locomotives being done
in the unit.

10. PRODUCTION:-
 Rehabilitation, Up gradation of WDM-2 locos to WDM-
3A(3100HP) .
 Manufacturing of new WDM-3D locos.
 Supplying New/Remanufactured Power Packs to Zonal Railways.
 Supplying 240 types of high precision & critical components to
Zonal Railways as maintenance support.
 Supplying WDM3A/ WDG3A/ WDM3D Motorized Wheel sets to
Zonal Railways.
 Supply of rehabilitated Engine Blocks & Traction Machines to
Zonal Railways.
 Nodal Agency for Rehabilitation of high HP Turbochargers.
 Supply of all types of Carbon Brushes of Diesel Locos to Zonal
Railways

11. FURTHER GOALS
 DMW & Parel to manufacture 50 ALCO locos in 2012-13, 75 in
2013-14 & 100 from 2014-15 onwards.
 To manufacture fuel efficient locos using the EFI technology.
 To use the generator control transfer system on more locos
(testing).
 To manufacture EMD Locos from 2017-18 onwards.
 To establish series manufacture of EMD Traction Alternators after
rigging up facilities for testing of EMD TA’s.(in progress)
 To develop overhauling facilities of Traction motors for EMD
locomotives (in progress).
 Manufacturing locomotives ordered by U.S.A.
 Manufacturing of WDM 3F (3600 hp.) locomotives by next year(
under testing).

12. Layout:

13. List of shops
 T.T.C. (Technical Training Centre)
 L.R.S. (Loco Rebuilding Shop)
 P.P.S. (Power Pack Shop)
 L.M.S. (Light Machine Shop)
 C.B.S. (Carbon Brush Shop)
 S.S.S. (Super Structure Shop)
 L.T.S. (Loco Testing Shop)
 T.M.S. (Traction Machine Shop)
 A.B.S (Air Brake Shop)
 H.M.S. (Heavy Machine Shop)
 T.R.S (Tool Repair Shop)
 B.S (Bogie Shop)
 L.P.S (Loco Paint Shop)
 Loco Dismantling
 T.S (Transmission Shop)
 Administration Block

14. L.R.S (LOCO-REBUILDING SHOP)

15. P.P.S (POWERPACK SHOP)

16. Powerpack shop:
 The shop can be divided into three sections:-
Stripping of the power pack
Assembly of the powerpack
Testing of the powerpack.
 The shop is well equipped with high capacity over head
remote controlled cranes and engine test beds.
 Testing of lube oil, water pumps, fuel injection pumps,
turbochargers and other assemblies also take place in
this shop.

17. L.M.S (LIGHT MACHINE SHOP)

18. Light machine shop
MAIN PRODUCTS
 Gear sets
 Connecting rod assembly
 Main bearing caps
 Axles
 Cam shafts
 Armature shafts
 Beams
 FIP support

19. S.S.S (SUPERSTRUCTURE SHOP)

20. Superstructure shop
 The super structure includes the outer frame (body) of
the loco i.e. the cabin, front side, rear side and the
middle deck.
 The shop deals with the repair, welding and machining
of old frame structure. However the newer ones are
ordered from outside.
 It is well-equipped with sheet cutting CNC machines and
welding sets.

21. T.M.S (TRACTION MACHINE SHOP)

22. Traction machine shop
 This shop deals with the traction motors and alternators.
 Traction motors and alternators after removal are brought
for any kind of repair or winding to be done.
 This shop also supplies traction motor sets to the other
production units.
 Both AC and DC traction motors are repaired.
 Repair facilities for GM-EMD traction alternators and motors
as well.

23. H.M.S (HEAVY MACHINE SHOP)

24. Heavy machine shop
 Machining and repair work of the engine block takes place
here.
 Key features of this shop include PROCECO WASHING
PLANT, CNC MACHINE ROOM, ROBOTIC WELDING,
HOT FURNACE FOR STRESS RELIEVING.
 Repairing of the traction motor housing (magnet frame),
main cap bearings also takes place here.
 5 heavy duty CNC machines installed:-
PAMA CNC (ITALY) -2 Nos.
HMT CNC (INDIA) -1 No.
BMT CNC (ROMANIA) -1 No.
G&L (GIDDING AND LEWIS) (SCOTLAND) -1 No

25. BOGIE SHOP

26. Bogie shop
 Here wheels, bearing, traction motor, axle boxes, gear are
assembled to the axle.
 Turning of wheel takes place.
 This assembly is then assembled to the bogie and supplied to the
L.R.S.
 Products of this shop includes motorized wheel sets, assembled
bogies for WDM 3A and WDM 3D.

27. WDM-3A (UPGRADED WDM 2 SERIES)
SPECIFICATIONS:
Re-builder: Diesel Loco Modernization Works,
Patiala, India (DMW) as WDM 3A (upgraded version
of WDM 2 family)
Power: 3100 hp
Max. Speed: 120km/hr.
Engine: ALCO 251-C (16 cylinders) power pack; 1050
rpm max / 400 rpm idle; direct fuel injection.
Fuel injector: BOSCH
Turbocharger: GE.
Governor: MICRA SERVO DRIVES (micro controller
based actuator).
Transmission: Electric with BHEL TA 10102 CW
alternator, 1050rpm, 1130V, 4400A.
Wheel set: Co-Co type.
Fuel tank capacity: 5000 ltrs.
Shock absorbers: Spring type and Beam type

28. WDM 3D (NEWLY BUILT 3300 HP)
SPECIFICATIONS:
Builder : Diesel Loco- Modernization Works,
Patiala (DMW), DLW(Varanasi)
Power : 3300 hp.
Max. speed : 120 km/hr.
Engine : ALCO 251-C (16 cylinders) power
pack; 1100 rpm max / 400 rpm idle; direct fuel
injection.
Fuel injectors : WOODWARDS
Turbocharger : GE
Governor : MICRA SERVO DRIVES (micro
control based actuator)
Transmission: BHEL alternator 1100 rpm and
traction motors
Wheel set: Co-Co type
Fuel tank capacity : 6000 ltrs
Shock absorbers: Spring type and Oil
shockers.

29. THE DIAGRAMMATICAL PROCESS LAYOUT
The process layout Loco in
Loco Stripping
Under frame cleaning
and repairs
Re-cabling, re-piping,
brakes and loco assembly
Loco
Testing
Frame repairs and Bogies
furnishing
Bogie
assembly and
testing
Loco
Despatch
Power pack
Component reclamation and
Engine Assembly
Power pack
assembly and
testing
Traction motors
Engine
Block
Engine block re-building
Magnet frame reclamation
Rewinding of TG
Rewinding of TMs
Traction alternator
r

30. PROJECT ASSIGNED
 TO STUDY THE COMPLETE
PROCESS OF
REMANUFACTURING OF
ENGINE BLOCK

31. THE ENGINE BLOCK
Manufactured at DIESEL LOCOMOTIVE WORKS, VARANASI (DLW).
Total no. of 20 bores for 2 cam shafts and 9 for crank shaft.
Two ends –free end (connected to pumps, expressor, radiator fan etc.) and
generator end (connected to the generator).
A thrust bearing provided at the generator end to absorb any shocks or jerks
from the generator end.
Serration pads are provided on the saddle portion to get meshed with those on
the main cap bearing.
Sleeves are provided on the cam and crank bores made up of aluminum to
withstand high wearing and operating temperatures.

32. THE ENGINE BLOCK
AIR GALLERY
WATER
GALLERY
CAM BORE
• SADDLE (forging manufactured from steel-IS: 1875).
• SPLINE (fabricated from low carbon steel plates-IS: 2062)
• TOP DECK-75mm (mild steel)
• MIDDLE DECK-45mm (mild steel)
• SIDE SHEET-22mm (mild steel)
• INSIDE WALL-16mm (mild steel)
TOP DECK
MIDDLE DECK
SIDE SHEET
SADDLE
FOUNDATION
RAIL
SPLINE
CRANK BORE

33. Brief procedure…
 Thick steel plates are cut by heavy flame cutting machines.
 Then these plates are welded over the saddle portion by heavy ARGON-CO2
(MIG) welding at the joints.
 These plates are welded together (fabricated) by Submerged arc welding.
 Then all types of boring, drilling and machining takes place on heavy CNC
machines.
 All these processes are carried under high degree of accuracy and tested by
the latest technology (ultrasonic and x-ray).
 Some of these blocks are then sent to DMW, PATIALA to carry out
machining and to be installed on new locos or to replace the old ones.

34. Areas prone to defects
 Lamination crack in the plate at any location of the engine block.
 Crack in saddle, serration pads.
 Crack in crank bearing joints.
 Crank and cam bores.
 Fuel injection pumps (FIP) support section.
 Water and air galleries.
 Damaged holes.

35. Operations involved in engine block
remanufacturing:-
Washing Stripping
Stress relieving Inspection
Pre-inspection
Machining
Main bearing
cap machining
Final washing
Dispatch
Welding
Alignment test
Honing,
deburring
Surface
grinding

36. Stripping
The powerpack is disassembled in PPS and the engine block is sent to HMS.
In HMS following parts are removed:-
MB caps
Cam bore sleeves
Cylinder liners
Various studs around cylinder

37. PROCECO PLANT. This plant
consists of a cleaning tank, one boiler
and cleaning solution.
 Additives- detergent
(caustic,washing soda)
 Pressure - 80-125 psi
 Operating temperature – 1800f
 Boiler - fire tube boiler, nozzle
type
 Fuel used- Light diesel oil.
 Voltage - 59 volt.
Washing

38. Pre-inspection (D.P.T)
DYE PENETRATION TEST (D.P.T)
AREAS: top deck, the serration pads, the
saddle and the joints to locate the cracks.
MATERIALS USED:
•Penetrant {a red chemical which collects
itself near the crack}
•Cleaner {to clean the surface}
•Developer{a white chemical that helps to
highlight the accumulated red dye}
PROCEDURE
•Apply cleaner followed by the penetrant.
•Again apply cleaner to remove the
excess dye.
•Now apply the developer, red colour
coming out indicates crack.
Red colour in yellow indicates crack

39. Pre-inspection (hydraulic test)
HYDRAULIC TEST
AREAS: locating any kind of damage in
the air and water galleries.
PARAMETERS:
Water temperature - 80 degree
Water pressure - 8 kg/cm2
PROCEDURE
•The galleries are entirely closed and
high pressure water is passed into these
galleries through one inlet and taken out
from the other.
•The block is rotated with the help of
side plates and crane.
• In case of any crack in the galleries, the
water will leak through the crack and
hence it can be located easily.

40. Welding
ELECTRIC ARC WELDING
Flux coated electrodes are
used.
The flux forms the slag with
the impurities that are
generated during the welding.
The electrodes are of mild
steel with coating.
Done manually, especially
plug welding

41. Welding
MIG WELDING
MIG-CO2 (ARGON-82% & CO2
-18%) welding.
A continuous feeding system
feeds the copper coated MS
electrode.
Carbon dioxide and argon
mixture is used as the inert gas.
Done robotically on Top deck
bores, Middle deck bores, Crank
bores, Cam bores
Done manually on cracks as
per record(serration pads).

42. Basically annealing, to get uniform stress
concentration, induce ductility and remove
brittleness.
Procedure:
Furnace is preheated.
Temperature is set at 6400-6500C.
Then compressed air valve is opened and
the burner is started after closing the door.
The engine block is soaked for 4 hours
once temperature of 6500C is reached.
Burner is then stopped.
Cooling fans are stopped at 4000C.
After this slow cooling of the block takes
place for the next 48 hours.
The doors of the furnace are opened at
2000C.
The Engine block is pushed out when
furnace temperature is at 1500C.
Stress relieving

43. As said earlier the room is installed
with 5 heavy duty CNC machines.
The following operations are done
here:-
Foundation rail machining.
Saddle pad facing.
Crank and cam bore machining.
Top deck and Middle deck boring.
Serration cutting.
Drilling of holes on side plates, end
plates and top deck.
Repair of the defected holes.
Machining

44. •Honing is an abrasive machining process
that produces a precision surface on
a metal workpiece by scrubbing
an abrasive stone against it along a
controlled path.
•Honing is primarily used to improve the
geometric form of a surface, but may also
improve the surface texture.
•In simple terms honing is the process of fine
removal of the material to gives higher
degree of accuracy and smoothness.
Honing

45. Alignment test
•In the alignment test, a steel rod called the MANDREL is made to pass through
the lubricated crank (fitted with the main bearing caps) and cam bores.
•It is made to enter through one end and removed from the other end.
•A thin sheet is passed through it giving a suitable clearance.
•In case of unsatisfactory results, machining is done on the required portion

46. M.B cap machining
The main bearing caps are replaced with the new ones, every time overhauling occurs.
In the L.M.S rough milling cutting and facing is done. Since the fitting takes place in
H.M.S, the following operations are done here:-
•Facing
•Serration milling
•Crank shaft boring
•Oil hole drilling
•Drilling stud holes

47. Dimensions of the block after
remanufacturing
 Crank Bore Diameter - 9.0355 - 9.037
 Cam Bore Diameter - 4.750 - 4.7515
 Height Of The engine Block - 36.250 ± 0.010
 Total length of engine block - 161.125
 Distance b/w Foundation Rail To Saddle Pad - 2.704 - 2.706
 Distance b/w Crank Bore Centre To Liner Seat - 32.480 - 32.486
 Serration Pitch (MB CAPS/SADDLE PAD) - 0.250 ± 0.0002
 Serration Depth (MB CAPS/SADDLE PAD) - 0.059 - 0.064
 G.M Dowel Hole Diameter - 1.500(+0.001)
 Cylinder Liner Bores:-
 Top Deck Bore Diameter - 10.750 - 10.752
 Middle Deck Diameter - 10.621 - 10.623
 Distance b/w Top Deck To Middle Deck - 13-25/64
 Liner Seat Diameter - 12.000 ± 0.010
 Radial Distance On End Plates (cam and crank bores) - 19.500 (approx.)
 Cylinder Head Stud Holes Diameter - 1-1/8
*All the above values measured in inches
*For measuring the diameters upto 4th decimal place (mm/inch) DIAL BORE GUAGES of different ranges are used.
Cam shaft diameter - 2-6 (inches)
Crank shaft diameter - 6-10 (inches)
Cylinder diameter - 10-14 (inches)

48. CNC PAMA MACHINE

49. PAMA SPECIFICATIONS
 Name - PAMA CNC (MW 1156)
 Make - PAMA, ITALY
 Spindle diameter - 160 mm
 X-stroke - 11000mm(longitudinal)
 Y-stroke - 3000mm(vertical)
 Z-stroke - 1200mm(spindle)
 Rotation - 360 degree
 Accuracy - 0.008mm
 Total no. of tools - 60
 Power - 195 KW(supply) 400 V, 50 Hz
 Crank boring max. speed - 500 rpm, transmission ratio-1:1
 Cam boring max. speed - 500 rpm, transmission ratio-1:1
 Total weight of component - Engine block 6 ton(6000 kg)
 Components manufactured - ALCO 12 and 16 cylinder engine blocks
 Activities performed- Machining of foundation rail
Serration milling
Top deck cylinder liner bore
Middle deck cylinder liner bore
Crank and cam boring

50. The powerpack
The engine block after whole remanufacturing process is sent to the P.PS to be assembled into the POWERPACK.
The main components assembled to the engine block are:-
 Sump (engine base)
 Connecting rod assembly
 Crank shaft
 Cam shaft
 Cylinder head
 Cylinder liner
 Piston
 Turbocharger and After cooler
 Lube oil and fuel pumps and filters
 Governor
 Crank case exhauster motor
 Over speed trip
 Inlet and exhaust manifolds
 Gears
 Alternator
 Auxiliary and exciter generator
 Fuel injection pump
 FIP support
 Fuel injector
 Cylinder sleeve
 Fuel and oil pipes

51. IMPORTANT POINTS
 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 22 degrees before TDC.
 Performing phasing (for FIP timing) and tappet clearance of 34 thou.
 Proper fitment and securing of the cylinder head on the engine block.
 Fitment of crank shaft, cam shaft and piston assembly
 Alignment of traction alternator with the crank shaft.
 Ensure proper functioning of valve level and FIP.
 Smooth functioning of fuel control shaft.
 Elongation of main bearing studs 0.040±0.0020 inch. at 100 ft.lbs
 Elongation of connecting rod bolts 0.022 inch.
 Fittings as per torque values.
 Applying sealants, grease and gaskets wherever required.

52. DEVELOPMENTS MADE
 Use of pistons with steel caps to withstand high pressure
and temperature at higher power and achieve higher
compression ratios.
 Switching from DC-DC traction to AC-DC traction .
 Higher power traction motors.
 Better water and lube oil pumps with higher speed.
 Electronic fuel injection (EFI).