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BRIEF INFORMATION OF INSEIN WORKSHOP

 BRIEF  INFORMATION  OF  INSEIN  WORKSHOP

OBJECTIVES OF INSEIN LOCOMOTIVE WORKSHOP

1.         The constructional work was started in the year 1870 and completed in 1875. The original aim and object of the Insein Workshop was to carry out the heavy repair of Steam Locomotives.  But the works had been expanded for the repair of Electric Generating Sets, I .C Engines, Pumps & Compressors for watering arrangements. A Foundry Shop had also been erected for manufacturing of Steam Locomotive Parts.

 

LOCATION

2.         The workshop is situated at the western side of the Insein Railways Station, which is about ten miles from Yangon downtown. It is also at a distance of one furlong from the Yangon - Insein Road. The area of the Workshop compound is 26.78 acres ( 0.1084 sq.km ) including the Gas Plant.

MAIN SHOPS

3.         The main building consists of the following shops at the time of construction.

            (1)        Tool Room

            (2)        Machine Shop

            (3)        Fitting Shop

            (4)        Blacksmith Shop

            (5)        Boiler Shop

            (6)        Erecting Shop

            (7)        Internal Combustion Engine Shop

            (8)        Electric Shop

            (9)        Stores Office

SEPARATE SHOPS

4          The following shops are situated separately:-

            (1)        Works Manager Office and Time Office

            (2)        Foundry Shop

            (3)        Mill Wright Shop

            (4)        Tin and Copper Shop

            (5)        Store Godowns

 

REMODELLING OF  INSEIN  WORKSHOP        

5          Nearly half of the existing Erecting Shop had been modified to accommodate the complete assembly of mechanical and electrical works, Paint Shop and Offices. Part of the Boiler Shop had been modified for the repair of underframes and construction of bonnets. Diesel Parts Manufacturing Shop had been extended and Tin & Copper Shop had been remodelled for the repair of radiators and pipe works. Part of the Internal Combustion Engine Shop was utilized for Bogie repairing works. The existing Electric Shop was converted into Main Generator and Traction Motor repairing shop.

 

6          The Electric Shop had been transferred to the Composite Brake Block Manufacturing Shop, which had been shifted to Pazundaung. Layout plan of working is as map: - 

INSEIN LOCOMOTIVE WORKSHOP

 

 

                                         

 

 FRENCH  LOAN

(a)        Rebuilding, Repowering and Midlife Overhauling of (62) numbers of 900, 1200 and 1600 Horse Power Diesel Electric Locomotives in Myanma Railways with the collaboration of French Engineers from Messrs. GEC Alsthom during the year 1981 - 1991.

 

OECF  LOAN

(b)(i)    In Myanma Railways Modernization Project Stage I, (7) numbers of 500 Horse Power Diesel Hydraulic Shunting Locomotives, (2) Nos in fully erected and (5) Nos in semiknock - down conditions, were purchased. (2)  Nos in fully erected Locomotive were already put in commission and posted at the Mahlwagon Diesel Locomotive Depot for the shunting and marshalling services in Yangon Suburban Area with effect from June 20, 1986. Construction of (5) Nos, semi-knock-down Locomotives was completed and those were put in commission in February 1987.

 

    (ii)    In Myanma Railways Modernization Project Stage II, (5) numbers of 500 Horse Power Diesel Hydraulic Shunting Locomotives, (2) Nos in fully erected and (3) Nos in heavy knock - down conditions, were purchased. These Locomotives were constructed successfully in Insein Workshop under the technical co-operation between Myanmar and Japanese Engineers. (2) Nos of fully erected Locomotives were put into services in February 1989 and (3) Nos of Heavy knock - down Locomotives were put into services in October, 1989.

 

OPEC  LOAN       

(c)(i)    In  Myanma Railways, (6) numbers of 900 Horse Power Diesel Electric Locomotives were repowered  with Wartsila Diesel Engine UD 30 V 12 R 5  RVI under the OPEC Loan Phase I and  put into services in Yangon Circular and Suburban Area in 1994.

    (ii)    With the OPEC Loan Phase II, (7) numbers of 900 Horse Power Diesel Electric Locomotives for Yangon Circular and Suburban Services were repowered with Caterpillar  Diesel Engine 3512 DITA . The project was completed at the end of March 1999.

 

8.         The above projects were carried out by the railways engineers, supervisors, skilled and semi skilled workers with the technical co-operation of Japanese and French Experts. Some of the Myanma Railways’ engineers and supervisors were trained in the Republic of France, Federal Republic of Germany, Japan , China and India by studying “ On job Training Courses ” sponsored by the locomotive manufacturers. Skilled workers also have field work experiences in  the previous successful projects of rebuilding and mid - life overhauling of Diesel Locomotives in Myanmar since 1981.

INDIAN LOAN    

9.         During the year 1999, a contract for purchasing the (10) Nos. 1350 HP , good secondhand            locomotives from the Indian Railways and a contract for setting up of traction motors, generators rehabilitation and manufacturing shop were made by Myanma Railways with the Indian Loan , 8 million US$. A contract was signed with the Rotomac Electricals Private Limited  of India  for the traction motors/generators rehabilitation and manufacturing shop and it was constructed  in the Insein Workshop by re-modeling the existing shops. The main stores area was transfered to the Diesel Parts Manufacturing shop and the traction motors/generators rehabilitation and manufacturing shop was constructed in place of the main stores area.

 

REPOWER OF ALSTOM DIESEL ELECRTIC LOCOMOTIVE BY CHINA MADE DIESEL ENGINE (A 8 V 190 ZL)

INTRODUCE TO JINAN DIESEL ENGINE CO. LTD., (JDEC) CHIDONG SERIES 3000 DIESEL ENGINE

10.       Jinan Diesel Engine Co., Ltd. (JDEC) is one of the largest manufacturer in china, specialized in internal combustion engine owned by China National Petroleum Corporation (CNPC), which was founded in 1920 with more than 2000 employees. Product have the feature of high efficiency, compact structure, convenient maintenance, suitable and long life operation and good economic performance. The products are widely used in oil drilling, stand by and continuous power station, locomotives, vessels, etc. With a fast development of the petroleum industry of Chidong a new type of diesel Engine 3000 series, which is now advanced  both in the technical character and the operation performance of the current as drilling industry was developed. It is made on the basic of the diesel engine of 190 type developed by AVL Co. Ltd. Austria and Jinan diesel engine Co., Ltd.

 

 

 

IMPLEMENTATION OF REPOWERING

11.       The following works are required for repowering -

a.         Preparing the frame to receive the new engine

b.         Coupling the engine together with the main generator using the new

coupling and the new intermediated adaptation part

c.         Mounting the engine on its base frame

d.         Fitting the complete power set on the frame for the locomotive

e.         Fuel, Oil, water circuit modifications

f.          Fuel filter pre-lubrication pump bracket fabrication and installation on

the locomotive

g.         Electric wiring modification arising out of repowering and engine

electric connection

h.         Air intake, exhaust duct and new stack fabrication and mounting on the

locomotive

i.          Engine room partition doors fabrication and mounting

j.          Static tests

k.         Power Test

 

 

 

NEW LOCOMOTIVE CONSTRUCTION

12.       The Insein Locomotive Workshop has constructed 1200 HP Diesel Electric Locomotives, DF.1200-01 was completed at (19.04.2007), DF.1200-02 was completed at (25.02.2008), DF.1200-03 was completed at (16.12.2009), DF.1200-04 was completed at (18.01.2010), DF.1200-05 was completed at (16.02.2010), DF.1200-06 was completed at (23.03.2010) , DF.1200-07 was completed at (10.05.2010) and  DF.1200-08 was completed at (30.06.2010).

DF.1200- 05 (DEL) (MR)

 

DF.1200- 05 (DEL) (MR)

 

DF.1200- 07 (DEL) (MR)                  DF.1200- 08 (DEL) (MR)

 

Equipments Install on Locomotive

                                                                            

REPOWER PROJECT FOR 2000 HP DIESEL ELECTRIC LOCOMOTIVES WITH LOCAL MANUFACTURED DIESEL ENGINES

13.       Myanma Railways has been repowered and introduced 1200 HP ALSTOM diesel electric locomotives replaced with China made JINAN (JDEC) diesel engine, by Myanma Railways’ engineers without original locomotives manufacturers. And then, Myanma Railways tried to repower with local manufactured diesel engines to find the alternative ways of repower and to reduce the costs.

            Myanma Railways are implementing the repower project, existing SEMT (PIELSTICK) and CATERPILLAR diesel engines replaced by local manufactured MOI 16 V 170 diesel engines, for the 2000HP ALSTOM D.E.L and 2000 HP DALIAN D.E.L in Insein Locomotive Workshop. MOI 16V 170 diesel engines were manufactured in Thargaya Diesel Engine Factory under the Ministry of Industry, joint cooperate with ZIBO Diesel Engine company, China.

 

COMPARISON OF DIESEL ENGINE’S CHARACTERISTICS

MOI 16V 170 (1500 rpm) Vs SEMT (PIELSTICK)

 

Srl No.

Characteristics

Engine Type

MOI 16 V 170

(ZIBO)

SEMT (PIELSTICK)

12 PA 4 185 VG

1

Maker

MOI Engine

Pielstick (France)

2

Cylinder Arrangement

 V 60°

V Type 90° angle

3

Bore

170 mm

185 mm

4

Stroke

200 mm

210 mm

5

No. of Cylinder

16 Nos.

12 Nos.

6

Compression Ratio

14.5

13.5

7

Total Cubic Capacity Compression Rate

72.63 L

67.8 L

8

Power at 1500 rpm

1470 kW

1470 kW

9

Operation Method

Four-Stroke Cycle, Single Acting

Four-Stroke Cycle, Single Acting

 

Srl No.

Characteristics

Engine Type

MOI 16 V 170

(ZIBO)

SEMT (PIELSTICK)

12 PA 4 185 VG

10

Combustion Method

Direct Injection

Pre Combustion

11

Cooling Method

Water Cooling

Water Cooling

12

Direction of Rotation                           
(View from Flywheel End)

C.C.W

C.C.W

13

Supercharger Turbo Blower

2 Nos.

1 No.

14

Air Cooler

 1No.

 2 Nos.

15

Diesel Oil Consumption

200 g/kw.h

237 g/kw.h

16

Oil Consumption

1.0 g/kw.h

-

17

Weight of Engine Dry Specific Weight

8780 kg

5400 kg

18

Oil Sump Capacity

240 L

240 L

19

Cylinder Block Water Capacity

100 L

100 L

20

Mean Piston Speed

10.67 m/sec

10.5 m/sec

21

Governor Type

Electronic 

Mechanical

22

Height of Engine

1800 mm

1865 mm

23

Width of Engine

1900 mm

1450 mm

24

Length of Engine

3500 mm

2539 mm

25

Idling Speed (min: Steady Speed)

720 rpm

720 rpm

26

Ignition Speed

120 rpm

120 rpm

 

MOI 16V 170 (1800 rpm)   Vs    CATERPILLAR

 

 

Srl No.

Characteristics

Engine Type

MOI 16V 170

 (ZIBO)

CATERPILLAR

CAT 3516 DITA

1

Maker

MOI Engine

Caterpillar (USA)

2

Cylinder Arrangement

 V 60°

V Type 60° angle

3

Bore

170 mm

170 mm

4

Stroke

200 mm

190 mm

5

No. of Cylinder

16 Nos.

16 Nos.

6

Compression Ratio

14.5

13

7

Total Cubic Capacity Compression Rate

72.63 L

69 L

8

Power at 1800 rpm

1618 kW

1600 kW

9

Operation Method

Four-Stroke Cycle, Single Acting

Four-Stroke Cycle, Single Acting

10

Combustion Method

Direct Injection

Direct Inwvjection

11

Cooling Method

Water Cooling

Water Cooling

12

Direction of Rotation                           
(View from Flywheel End)

C.C.W

C.C.W

13

Supercharger Turbo Blower

2 Nos.

2 Nos.

14

Air Cooler

 1No.

 1No.

15

Diesel Oil Consumption

200 g/kw.h

209 g/kw.h

16

Oil Consumption

1.0 g/kw.h

1.0 g/kw.h

17

Weight of Engine Dry Specific Weight

8780 kg

7640 kg

18

Oil Sump Capacity

240 L

402 L

19

Cylinder Block Water Capacity

100 L

300 L

20

Mean Piston Speed

10.67 m/sec

11.4 m/sec

21

Governor Type

Electronic 

Mechanical

22

Height of Engine

1800 mm

1716 mm

23

Width of Engine

1900 mm

1703 mm

24

Length of Engine

3500 mm

3366 mm

25

Idling Speed (min: Steady Speed)

720 rpm

600 rpm

26

Ignition Speed

120 rpm

120 rpm

 
         

New MOI 16 V 170 Diesel Engine                     Old CATERPILLAR Diesel Engine 

 

CONSIDERATION OF LOCOMOTIVES REPOWER PROJECT

The following facts should be considered for repower of locomotives;

                  - Locomotives General Layout and Arrangement

                  - Axle Load

                  - Locomotive total weight

                  - Engine’s Dimension; Length, Width, Height

                  - Maximum Moving Dimension (MMD)

- Coupling Adaptation System of Diesel Engine Vs Traction Alternator / Generator  (Single Bearing or Double Bearing Type)

                  - Diesel Engine’s Performance Curve

                  - Locomotive Control System

- Diesel Engine Governor System (Mechanical or Hydraulic or Electric or   

  Electronic)

                  - Direction of Rotation of Diesel Engine and Rotating Machines

                  - Condition of Major Components

                  - Existing Auxiliary Machines

                  - Brake System

                  - Coupler and Draft Gear Type

                  - Overhauling capacity for unchanged components and parts

                  - Other necessaries

 

IMPLEMENTATION FOR REPOWER

            The following works are required;

-     Preparation and modification of the locomotive frame to receive the new diesel engine

-     Coupling and adaptation of the Main Alternator Vs diesel engine (direct

      coupling for Single Bearing Type Alternator, Coupling with elastic flexible adaptation unit     for Double Bearing Type Alternator)

-     Installation of the Engine and Alternator set to the locomotive frame

-     Modification of the drive system from engine to the auxiliary machines

-     Modification of the Auxiliary Machines and their foundation if necessary

-     Modification of the Intake air filter and duct system

-     Modification of the exhaust chimney of engine

-     Modification of the cooling bonnet and water line piping

-     Modification of the pre-lubricating oil system with additional pump and

      motor set

-     Modification of the fuel pipe line 

-     Modification of the air pipe and pneumatic pipe lines if necessary

-     Modification of the control circuit for new engine governor system.

-     Modification of the electrical control cable wiring and power cable wiring

      to synchronize existing locomotive control and engine’s performance

-     Modification of the engine monitoring system in the operator cabinets

-     Testing of the static system before engine cranking

-     Cranking of the locomotive

-     Load testing in water resistance test room to meet the required output

      power curve

-     Testing of the locomotive parameters and safety devices

-     Running test in workshop on test track

-     Running test in main line

-     Running test in hill section (ghatt section) with load

-     Transfer to outstation locomotive depot / shed

 

 

 

LOCOMOTIVE CHARACTERISTIC AFTER REPOWERED

 

Technical Specification for DF - 2003 {Repower with MOI Engine 16 V 170 }

 

Type of Locomotive                           :           Diesel Electric Locomotive

Track Gauge                                        :           1000 mm        

Wheel Arrangement                            :           Bo Bo Bo

Horse Power                                       :           2000 HP

Max: Speed                                         :           90 kmph (56 mph)

Tractive Effort (Max:)                                    :           24500 daN (245 kN)

(Continuos)                                         :           15480 daN (154 kN)

Gear Ratio                                           :           91:20

Min: Radius of Curvature                   :           (28 Degree)(62.4 m)

Coupler Type                                      :           ABC

Loco Weight                                       :           75 Tons

Fuel (Capacity)                                   :           3200 Litre

Lubricating Oil (Capacity)                  :           240 Litre        

Overall Height                                    :           3505 mm

Overall Width                                     :           2816 mm

Overall Length                                    :           15683 mm

Engine                                                 :           MOI 16 V 170 (ZIBO)

Main Alternator                                  :           AT4 52A4 (Alstom)

Traction Motor                                    :           TA 669 D2 (Alstom)

Auxiliary Alternator                            :           25 AS (Statodyne) (Alstom)

Battery                                                :           74 VDC, KFH 160 P NI-CD (India)

Brake System                                      :           Air, Vacuum Brake, Parking Brake &

                                                                        Rheostatic Brake        

Air Compressor                                   :           W 1.6/9 (Beijing Nankou)

Vacuum Exhauster                              :           2NMV (SPIROS)

Auxiliary Vacuum Exhauster              :           2 Z 120 (SPIROS)

Master Controller                                :           TM 450 (Alstom) 

 

 

Technical Specification for DF - 2024 {Repower with MOI 16 V 170}

 

Type of Locomotive                           :           Diesel Electric Locomotive

Track Gauge                                        :           1000 mm        

Wheel Arrangement                            :           Bo Bo Bo

Horse Power                                       :           2000 HP

Max: Speed                                         :           90 kmph (56 mph)

Tractive Effort (Max:)                                    :           24500 daN (245 kN)

(Continuos)                                         :           18500 daN (185 kN)

Gear Ratio                                           :           92:19

Min: Radius of Curvature                   :           (28 Degree)(62.4 m)

Coupler Type                                      :           ABC

Loco Weight                                       :           75 Tons

Fuel (Capacity)                                   :           3200 Litre

Lubricating Oil (Capacity)                  :           240 Litre        

Overall Height                                    :           3505 mm

Overall Width                                     :           2750 mm

Overall Length                                    :           15703 mm

Engine                                                 :           MOI 16 V 170 (ZIBO)

Main Alternator                                  :           JF 205 H ( Yongji, China)

Traction Motor                                    :           ZD 110 ( Yongji, China)

Auxiliary Excited Generator               :           JGL 405 E ( Yongji, China)

Battery                                                :           74 VDC, KFH 160 P NI-CD (India)

Brake System                                      :           Air, Vacuum Brake, Parking Brake &

                                                                        Dynamic Brake          

Air Compressor                                   :           W 1.6/9 (Beijing Nankou)

Vacuum Exhauster                              :           LPK 100-1V (Demag, China)

Auxiliary Vacuum Exhauster              :           LPK 50-1V (Demag, China) 

 

 

16.       The Workshop is administered by the General Manager, supported by the Deputy General Manager and Assistant General Manager. The sanctioned strength of the Workshop is (1537) and consists of the following:

            (a)        Officers                                                           (14)

            (b)        Supervisory Staffs                                          (85)

            (c)        Skilled Worker, Unskilled Worker &

Clerical Staffs                                                 (1438)

 

17.       Besides, manufacturing of Steam and Diesel Locomotive parts and fittings, Carriage and Wagon spare parts, various repairs and maintenance of workshop handling equipments, steel, cast iron and brass foundry works, domestic supply of water and electricity, etc.., are also carried out by the Insein Workshop.

 

18.     STAFF  WELFARE

a.         Housing

            Up to the year 2009 - 2012 ( 609 ) residential quarters for staff  and (16) bungalows for officers were provided. The total number of staff in the workshop at present is (897). In addition Myanma Rail ways has given all possible assistance to the staff.

 

b.       Allocating  of  Housing  Plots for the Workshop Employees

            Since the 1989-90 financial year, various schemes were launched in some major cities to provide housing plots for government servants, who had served the better of their lives in the carrier and for those who served and lived in Yangon area, with 15 or more years of service. They are entitled for buying a housing plot in the newly satellite town of Dagon Myothit. The price 8,000  Kyats for a plot 2,400 square feet area is only a fraction of the development cost and this can also be paid in installment spread over a five years period and also without any interest. With this scheme (405) Workshop employees have been allotted a plot of land each.

c.         Medical  Facilities

Myanma Railways has a medical department with a Chief Medical Officer and five Divisional Medical Officers. It has twenty nine dispensaries, scattered throughout the Railways lines. Forty seven Medical Officers and three Dental Surgeons are working at the dispensaries. There is one fifty bedded hospital near by Insein Locomotive Workshop. The Workshop staff, and the Myanma Railways staff and their families in Lower Myanmar Regions have the opportunity to use the hospital.

 

d.       Co - operative Credit Society

            Co - operative Credit Society, Yangon, which provides low interest credit and saving bank facilities and advanced loans.

 

e.       Staff Model Workers Scheme

            Staff Model Workers Scheme has been launched and implemented since   1988 - 89 with the aim to bring forth good workers. The yearly selection of model worker and sending them for recreational trips to interesting spots is part of Myanma Railways endeavours to promote the incentive and welfare of the workers. As a result, the model workers were awarded a one week vacation and a trip to a place like Chaung Tha, Bagan, Inle Lake and Setse. In the selection process, the workers were judged by their performances of work individually as well as collectively, the attitude fostered by them to wards their works and to their fellow workers and also by their personal characters.

 

 

 

f.       Awards for Workshop Employees’ Children

            Since 1988 - 89 children of workshop’s employees, who gained distinctions in the middle school and high school final examinations, have been given monetary awards. Similar awards were given to all railways children who stood first to third in their respective final examinations.

 

g.       Workshop Welfare Committee   

This committee is headed by the General Manager of the Workshop. All the officers and the responsible persons are in the executive committee. According to the committee activity profits are shared to the workers by supplying rice and cooking oil, wedding grants, funeral grants, temporary disability grants for the period in the hospital, utilizing for entertainments, sports,  library, and the teaching aids for the children.

 

h.       Sports

The sportground is situated near by the workshop, the railways interdivisional tournaments are arranged by the railways for the sports central committee. The internshop tournaments are arranged by the workshop committee yearly.

 

i.        Institute

The Railways institute is used for the recreation of workers and ceremonies such as Shinpyu, Wedding of the workers and their families.

 

19.     CONCLUSION

The Insein Locomotive Workshop was originally designed for overhaul of Steam Locomotive and production of Steam Locomotive’s spare parts. Since 1981-82, the workshop has started repairing of Diesel Electric Locomotive. By its long history, the workshop has the capability to construct and to rehabilitate the Diesel Electric Locomotive. Manufacturing of some Diesel Locomotive’s spare parts and complete rewinding of DC Electric Traction Motor has successfully been accomplished at this workshop.

 

PRODUCTION FACILITIES IN INSEIN LOCOMOTIVE WORKSHOP

 

PRODUCTION FACILITIES IN INSEIN LOCOMOTIVE WORKSHOP

 

 

PRODUCTION FACILITIES IN INSEIN LOCOMOTIVE WORKSHOP

        

Universal Testing Machine         Spectro Lab

 

       

Governor Test Bench               Fuel Injection Pump Calibration Machine

 

Transportation of Steam Locomotive Class ST & Bogie Tourist Saloon (B T S) From Yangon to Ywili (China) as a Goodwill Gift

 

                                                   

 

Transportation of Overweight & Oversize Equipments for

Ministry of Energy, Myanma Oil & Gas Enterprise From Yangon to No.(4) & No.(5) Fertilizer Plants

                                                  

                                                   

                                                   

                                                  

Transportation of Rail Bus From Yangon to Sittwe

                                                           

Transportation of Rail Bus From Yangon to Kyaing Tone

                                                                         

Transportation of Steam Locomotive Class ST, YB & Steam Crane 35TSC 9885 from Yangon to Kunming (China) as a Second Time Goodwill Gift (26.9.2012) 

                                                                

 

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